Caterpillar. Dealer service tools catalog (2018)

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Product Link Diagnostic Tool Group

Model Usage: All Cat models with Product Link

• Used to setup, test, and troubleshoot Product

• 312-5608 Main Harness connects to 312-5641

Attachment

Link system

Switch Box and 312-5609, 312-5610, or

312-5611 Stub Harnesses connect main

Warranty: Caterpillar ^®One Year

• Used with external 12 VDC or 24 VDC battery

harness to Product Link component being

power source

tested

• 312-5641 Switch Box used with various

harness assemblies to perform specific

Reference

diagnostic tests on unit being serviced

• NEHS1016, 312-5642 Product Link Diagnostic

• Comes complete with switch box, main

Tool Group

(power supply) harness, three stub harnesses,

and case with foam insert

Item

Part Number

Description

312-5641

Switch BoxAssembly

312-5608

Main Harness Assembly

312-5609

121 Stub Harness Assembly

312-5610

151/201 Stub Harness Assembly

312-5611

300/321 Stub Harness Assembly

—

312-5642

Product Link Diagnostic Tool Group

Not Shown

6V-7145

Case

—

317-9430

Foam Insert for 6V-7145 Case

Cable Assembly

Model Usage: All Models with Electronic

• Connects laptop computers without serial

NOTE: Because of its length, this cable will

Controls

ports to Communication Adapter II (see note)

work with Communication Adapter II only with

newer PC’s without a serial port. Older laptops

Warranty: Caterpillar ^®One Year

• Uses computers parallel port

will operate only with a shorter parallel cable,

• 25 pin, male-to-male, 7.6 m (25 ft) long

2 m (6 ft) long maximum.

Part Number

Description

225-5985

Cable Assembly

Serial Cable

Model Usage: All models with electronic

• Used to extend and adapt DB25 (25-pin)

• Larger individual wires and more robust cable

controls

connector to DB9 (9-pin) connector

provides longer service life

Warranty: Caterpillar ^®One Year

• Used with 275-5120 Communications Adapter

• Overall length: 7.6 m (25 ft)

II Group

Part Number

Description

321-4331

Serial Cable

1-66 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Data Link Cable Assembly

Model Usage: All Models Using Electronic

• Used to connect Communication Adaptor 3 to

• Works on ATA, CAT,J1939-11 and ethernet

Controls

the machine diagnostic interface

data links

Warranty: Caterpillar ^®One Year

• Works with 9- and 14-pin connectors

Specifications

• Provides Ethernet connector for machines

• Weight: 1.5 kg (3.3 lb)

with 14 pin diagnostic connector

• Length: 650 mm (25.6 in)

Part Number

Description

457-6114

DataLinkCable Assembly

Wireless Communication

Model Usage: All

European Union compliant, CE marked

• Uses service tool programs, Cat Electronics

Technician on J1939/11 high-speed data

Warranty: Caterpillar ^®One Year

• Used with 317-7485, Communication Adapter

link, CAT DataLink, or J1708 (ATA) vehicle

3 to wirelessly monitor communication

networks, or Dual DataLink

between engine and PC

• USB device connectivity options

• Includes cables, software CD, manual on CD

• Completely sealed connectors and enclosure

Part Number

Description

317-7492

Wireless Communication

Datalink Cable Assembly

Essential Tool

• Used to connect engine control module (ECM)

• Allows communication between service tools

and engine controls using various data links

Warranty: Caterpillar ^®One Year

• Overall length: 1900 mm (75.0 in)

such as J1939/11, Cat^®DataLink, and J1708

(ATA) vehicle networks

Part Number

Description

259-3183

Datalink Cable Assembly

JULY 2018 Diagnostic Tools

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Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Comm Adapter II Cable

Model Usage: All Models With Electronic

• Replaces discontinued 7X-1412 (ATA) and 7X-

• Connects either ATA data-link or the Cat^®

Controls

1570 (CAT) Adapter Cable Assemblies

data-link to disc. 7X-1700 Communication

Adapter

Warranty: Caterpillar ^®One Year

• Overall length: 3 m (18 ft)

Part Number

Description

139-4166

(CAT/ATA) Universal Cable

Adapter Cable Assembly (ATA/CAT Breakout T)

Model Usage: Engines without a diagnostic

• Used on machines whose engines are without

• Use to connect communication adaptor cable

service connector

a diagnostic service connector

to machine datalink

Warranty: Caterpillar ^®One Year

Part Number

Description

140-9442

Adapter Cable Assembly (ATA/CAT Breakout T)

USB Serial Adapter

Model Usage: All

• Used to provide a RS232 communication link

• Can be used to flash DataView designed to

for personal computers (PC’s) equipped only

work with 2000, Microsoft Windows XP, Vista

Warranty: Caterpillar ^®Six Months

with USB ports

Windows and Windows 7

• Can be used with 275-5120 Communication

• Includes software CD

Adapters

Part Number

Description

370-8059

USB Serial Adapter

Power Cable Assembly

Model Usage: 3406E, 3176B, 3116HEUI,

• Used to gain access to ADEM II ECM data, in

• Allows service tool to be connected directly

3126HEUI, C-10, and C-12 Engines

event that service tool will not communicate

to ECM to verify ECM operation - can also

at OEM connector

isolate a communication problem due to OEM

Warranty: Caterpillar ^®One Year

wiring harness

• Also provides means of powering service tool

while cranking engine

• Cable assembly has fuse protected power

clips to allow direct hook up to battery

• Replacement fuses available (8M-8948 Fuse,

15 amp)

Part Number

Description

399-7427

PowerCableAssembly

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Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Cable, RS-232

Model Usage: All models with electronic

• Replaces discontinued 7X-1688 Cable Group

• Used to connect a discontinued 7X-1701

controls

Communication Adapter I to RS-232 computer

• 4C-6805 Adapter (9 to 25 pin), part of

port (discontinued 7X-1701 Communication

Warranty: Caterpillar ^®One Year

discontinued group, is sold separately for use

Adapter I can now be purchased separately)

with older computers

Part Number

Description

7X-1425

RS-232 Cable

Connector

Model Usage: 3406 and 3176 Engines

• Usedto replace ECAP’splastic Port 1 socket

Board or (Without)

and mating connector with steel parts to

Pin No. (8C-4146)

To Pin On (3E-3423)

Warranty: Caterpillar ^®One Year

eliminate breakage

• 3E-3423 Connector is installed into ECAP

• Rework can be done by dealer or sent to the

Dealer Service Tools Division

(no connection)

Instructions for Reworking ECAP at

Dealership

• Enlarge diameter of connector mounting holes

No connection

D and E

by 0.41 mm (0.016 in)

Pin No. (8C-4146)

• Hole enlargement can be easily completed

Input Pre-Reg (B+)

with a file

Gnd Pre-Reg (B-)

• Move wires from plastic 8C-4146 Connector

Gnd Pre-Reg (Gnd)

to steel 3E-3423 Connector 1 wire at a time

DL- (DL-)

(no connection)

• Move wires on connector

RXL (RXL)

• Theother end ofthe wire isattached to the

DL+ (DL+)

Tx (Tx)

following locations - With Pre-Regulator

Prog (Prog)

Part Number

Description

3E-3423

Connector

Cable, EIS Loopback

Model Usage: All Engines with EIS (Electronic

• Used to allow EIS (Electronic Ignition System)

Ignition System)

control to test itself

Warranty: Caterpillar ^®One Year

Part Number

Description

7X-1713

EIS Loopback Cable

Service/Repair Parts

7X-6222

Plug

8T-8729

Connector Pin

8T-8730

Socket

8T-8735

Plug - Connector

8T-8737

Seal Plug

9W-0844

Socket

JULY 2018 Diagnostic Tools

1-69

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

ADT Payload Flash Cable

Model Usage: Articulated Dump Truck 725C,

• Used to connect a USB jump drive to the ADT

• Allows payload system to be reprogrammed

730C, 735C, 745C

payload system

Warranty: Caterpillar ^®One Year

Part Number

Description

Overall Length

449-4613

Cable Assembly, ADT Payload Flash

300mm(11.85in)

Communication Cable Assembly

Essential Tool

• Used for flash, upload, download, parameter

• Used with a laptop computer and WebGPI

adjustment, status communication with Sauer

software

Model Usage: Most Paving Products

Danfoss Controller (electric screed heat)

Warranty: Caterpillar ^®One Year

Part Number

Description

245-4121

Communication Cable Assembly

Communication Adapter Cables

Model Usage: CS-563E, CS-573E, CS-583E,

• Used to service various electronic components

• 3-pin Deutsch plug connects to CAN port

CS-663E, CS-683E, CS56, CS64, CS74, CS76,

and sensors on soil compactors

or COM port on machine (CAN/COM ports

CS76XT Soil Compactors

sometimes located behind fuse panel)

Item 1

Warranty: Caterpillar ^®One Year

Item 3

• CAN (DB9) to USB adapter

• Used on all models that contain a Sauer

• Used to service various electronic components

Danfoss Plus 1 ECM

and sensors on soil compactors

• Used with Sauer Danfoss Plus+1 Guide

• Replaces 309-5667

Service Tool software

• Used with 480-5264 and 300-7925 for

• Software available on our site

machines with the 9- or 14-pin service port

• Replaces 300-7924

connector instead of the 3-pin can port

Item 2

connectorCombination 9- and 14-pin service

• DB9 PC serial port to 3-pin receptacle Deutsch

port to 3-pin plug Deutsch adapter

adapter

Reference

• Used with 300-7924 to connect PC service

• REHS3302 Service Manual

tool to machine (DB9 connects to 300-7924

Communication Cable)

Item

Part No.

Description

Dimensions

Weight

480-5264

Communication Adapter Cable

300-7925

Communication Adapter Cable

484-9472

Communication Adapter Cable

200x200x100mm(8x8x4in)

2 kg (4.4 lb)

USB Cable

Model Usage: 735, 740, 740 Ejector

• A-Male to A-Male USB cable supports

• CMPD’s USB cable must be plugged into a

Multi-Purpose Display (CMPD) ECMs used on

USBport on the PC

Warranty: Caterpillar ^®One Year

Articulated Trucks

Specifications

• The new method of flashing will transfer

• USBA-Male to A-Male iteniary

the flash file over a USB connection using

• Length: 3 meter (10 ft)

Microsoft Active Sync

• Type: USB 2.0

Part Number

Description

371-3480

USB Cable

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Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Cable,Touchscreen Interface Communication

Model Usage: Machines and Engines Equipped

• Used to connect PC to Touchscreen

• Uses USB connection

with Touchscreen Information Display

Information Displays

• Overall Length: 5 m (15 ft)

Warranty: Caterpillar ^®One Year

• Used in conjunction with CAT ET to upload

new software

Part No.

Description

Application

318-8840

USB to Deutsch DT

CIODS and older displays with DT connector

381-5782

USB to AmpSeal

Displays with AmpSeal connector

Attenuator

Model Usage: All with DPF

• Used to perform the “DPF Soot Loading

• Temperature range -40 to 75°C (-40 to 167°F)

Sensor Functional Test”

Warranty: Caterpillar ^®One Year

• TNC jack (female) on both ends

• 20+/-0.5 dB fixed resistive attenuation from

• Length: 0.75 m (29.5 in)

1 MHz to 2 GHz

• Attenuator used for testing diesel particulate

• 50 Ohms impedance

filter (DPF) for cracks, leaks, and recovery from

• 1 W power handling capability

engine oil contamination

Part Number

Description

366-7782

Attenuator

Vacuum/Pressure Gauge

• Complete with 0.6 m (2 ft) of high quality

• 88.9 mm (3 1/2 in) compound gauge has a

hose, plus (3) fittings

multicolor dual scale dial with ranges from 0

to 68.9 kPa (0 to 10 PSI), 0 to 0.7 kg/cm² (0 to

• Hook-on gauge enables technician to hang

9.94 PSI) pressure and 0 to 70 cm (0 to 28 in)

gauge and hose assembly to free his hands

Hg vacuum

Part Number

Description

5P-6582

Vacuum/Pressure Gauge

• Complete with 0.6 m (2 ft) of high quality

• 88.9 mm (3 1/2 in) compound gauge has a

hose, plus (3) fittings

multicolor dual scale dial with ranges from 0

to 68.9 kPa (0 to 10 PSI), 0 to 0.7 kg/cm² (0 to

• Hook-on gauge enables technician to hang

9.94 PSI) pressure and 0 to 70 cm (0 to 28 in)

gauge and hose assembly to free his hands

Hg vacuum

Part Number

Description

5P-6582

Vacuum/Pressure Gauge

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Diagnostic Tools

ENGINETOOLS

Diagnostic Plug

Model Usage: 3126 HEUI Engines

• Used to troubleshoot HEUI pumps

Reference

Warranty: Caterpillar ^®Six Months

• Used with 9X-1484 Seal Kit

• REHS1281, Service Manual

Part Number

Description

219-2368

Diagnostic Plug

HEUI Engine Tool Group

Model Usage: 3116 HEUI and 3126 HEUI Engines

• HEUI diagnostic tooling - includes all

• Injector and IAPC valve removal and

necessary cables, harnesses, and electrical

installation tools

Warranty: Caterpillar ^®One Year

pin removal tools to troubleshoot the

• Modified injector clamp to aid in proper

electrical system, conveniently packaged in a

assembly and tightening of the jumper tube

separate plastic box within the group

• Necessary bit drivers and socket to work on

• Hydraulic diagnostic tooling - includes all

hard-to-reach components

necessary fittings, pressure gauge and hose,

• Double-ended offset feeler gauge for setting

and a special breakout tee to troubleshoot the

valves

hydraulic system - including the injection

actuation pressure sensor and control valve/

Group Includes:

pump combination

• Plug, Clamp Assembly

Part Number

Description

125-2580

HEUI Engine Tool Group

Parts List

123-4941

Valve Setting Gauge

125-2584

Hex Ball Driver

125-2588

Hex Wrench, 7/64 in

125-2589

Diagnostic Fitting

125-5902

Foam Insert GP

1U-5757

Hose Assembly

1U-7587

Pry Bar, 6inlong

3B-6768

Adapter - STR (NPTF)

3J-7352

Connector

3J-7354

Seal—O-ring— STOR for 8C-3446 (not pictured)

5P-0144

Fuel Line Socket

5P-0333

Crowfoot Wrench

5P-5008

Reducer 37° Flared

6V-7145

Case

6V-8397

O-ring Seal

6V-9508

Plug - ORFS

7J-0204

O-ring Seal

8C-7310

Adapter

8S-7169

Coupling-Pipe Hexagon

8T-0852

Gauge Group - Pressure

9S-8007

O-ring Plug

a. Warranty: Lifetime

Pressure Gauge

Item

Part Number

Description

—

8T-0840

Pressure Gauge

8T-0848

Gauge GP - Pressure (3)

1U-5554

Panel Assembly

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Diagnostic Tools

ENGINETOOLS

Engine Pressure Group

Model Usage: All Models

• 6V-6045 Accessories Case contains fittings

• 8T-0839 Differential Pressure Gauge range:

that can be installed in all 1/8 inch NPT

Upto 12 kPa [50 inches water (H2O)], as well

Warranty: Caterpillar ^®One Year

ports on Cat^®Engines for setting up pressure

as either 12 kPa (1.74 PSI) pressure or vacuum

• Used to check performance of turbocharged

taps for 1U-5470; 8T-0821 Tubing is easily

• All other gauges in group read directly in: kPa

diesel and natural gas engines and, with

connected to and disconnected from 1U-5470

and PSI

optional 1U-5554 Panel and 8T-0840 Pressure

panel and engine port fittings; internal O-ring

Gauge, to make operating adjustments to

• 8T-0840 Pressure Gauge range: 0 - 100 kPa

seals tubing outer diameter and internal collet

naturally aspirated gas engines

(0 - 30 inches Hg)

mechanism locks tubing into fitting

• Replaces discontinued 6V-3150 Engine

• Vacuum range: 0 - -100 kPa (0 - -30

• Optional 8T-0840 Pressure Gauge used to

Pressure Groups and 4S-6553 Engine

inches Hg)

measure intake manifold pressure on natural

Evaluation Test Group; contents of 6V-3150

gas and gasoline engines and to power

• Operating temperature range: -1° to 60°C (30°

still serviced, but contents of 4S-6553 no

balance natural gas engines in multiple

to 140°F) for differential pressure gauges.

longer serviced; 6V-3150 can be upgraded to

engine applications; mounts on optional

-18° to 71°C (0° to 160°F) for all other gauges

essentially same functional specifications of

1U-5554 Panel Assembly which can be

• Gauge accuracy: ±2 percent of full scale for

1U-5470 by installing optional 1U-5554 Panel

permanently installed in 1U-5470 Engine

differential pressure gauge. SAE Grade A

with either 0-200 kPa [0-60 inch mercury

Pressure Group; 6V-4045 cannot be stored in

(±1.5 to 1 percent of full scale for all other

(Hg)] 1U-5469 Pressure Gauge (0-60 inch Hg)

1U-5470 with optional gauge installed

gauges)

or 100-0-100 kPa (30-0-30 inch Hg) 8T-0840

• Optional slack tube 8T-0452 Water

Pressure Gauge

• Operating position: Position has no effect on

Manometer available for use with 1U-5470;

differential pressure gauge, if gauge has been

• Equipped with 4 different pressure

measures static, vacuum, or differential

mechanically adjusted to ZERO in the test

gauges that indicate pressure relative to

pressure over range of 500 mm to 500 mm

position (on all other gauges, position has no

ambient atmospheric pressure; require no

H2O for total range of 1000 mm H2O;

effect on accuracy)

measurement corrections due to atmospheric

stored in optional 8T-3153 Foam Block

pressure changes

• Pressure media: Differential pressure gauge

placed in lid of 8T-0841

- clean air and gases only (no liquids). All

• 8T-0848 Pressure Gauges used to measure

Specifications

other gauges - air, gases and liquids (oil,

fuel pressure, intake manifold pressure

• 8T-0848 Pressure Gauge range: 400 kPa

water, antifreeze, fuel, etc.)

on turbocharged diesel engines, cooling

system pressure and to power balance diesel

(58 PSI)

• Size: 390 x 310 x 190 mm (15.4 x 12.2 x 7.5 in)

engines in multiple engine applications

• 8T-0846 Pressure Gauge range: 1000 kPa

• Weight: 6.8 kg (15 lb)

(0-58 PSI)

(145 PSI)

NOTE: DONOTuseany acidsor other highly

• 8T-0846 Pressure Gauge used to measure oil

• 1U-5469 Pressure Gauge range of engine

corrosive liquids in the gauges.

pressure and air compressor cut-in and cut-

boost or positive intake manifold pressure: 0 -

out pressures (0-145 PSI)

200 kPa (0 - 60 inches Hg)

• Chart in case lid used to convert kPa or PSI to

inches of mercury as shown in Fuel Setting

and Related Information microfiche

JULY 2018 Diagnostic Tools

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Diagnostic Tools

ENGINE TOOLS

Engine Pressure Group (Continued)

Item

Description

Not shown

Form SEES5677 Conversion Chart

Not shown

Form NEEG2187 Title Decal

Part Number

Description

Use

Used with

Allows 1U-5470 Engine Pressure Group

to be connected to the oil pressure

C0.5, C0.7, C1.1,

Adapter, 1/8 -27 NPTF to

switch port on the listed engines. Adapter

102-6496

C1.5, C1.7, C2.2,

1/8-28 BSPTM

requires the removal of the oil pressure

C3.4

switch on these engines in order for oil

pressure readings to be taken.

DONOTuseany acids or other highly corrosive liquids in the gauges.

Item

Part Number

Description

—

1U-5470

Engine Pressure Group

Optional 8T-0840 Pressure Gauge

Parts List

8T-0841

Case

8T-0839

Differential Pressure Gauge

8T-0846

Pressure Gauge

1U-5469

Pressure Gauge

8T-0848

Gauge GP - Pressure (3)

4C-3974

Fitting - Union Bulkhead (8)

8T-0821

Tubing, 16 m (52.5 ft)

4C-3973

Fitting—Connector (male) (6)

4C-3972

Fitting— Male Elbow (Swivel) (6)

4C-3971

Union (2)

6V-6132

CableTie (4)

6V-6045

Case - Plastic Form SEES5575 Accessories Label

6V-6115

Packing Set Base

Water Manometer

Item

Part Number

Description

8T-0452

Water Manometer

8T-3153

Foam Block

Digital Pressure Indicator Cable

Model Usage: All

• Increases distance between pressure pickup

• Overall length: 12 m (40 ft)

and hand-held, digital pressure indicator

Warranty: Caterpillar ^®One Year

Reference

• Used with 198-4240 Digital Pressure Indicator

• NEHS0818, Using the 198-4240 Digital

• Allows technician greater freedom to move

Pressure Indicator Group

around during testing, especially when

working on large equipment

Part Number

Description

198-4229

Cable— DPI 40 ft (12 m)

1-74 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

Digital Pressure Indicator Group

Model Usage: All

• Used to measure vacuum, pressure,

• Battery life (approx.):

differential pressure, and temperature

- 1 transducer 108 hours

Warranty: Manufacturers One Year

- 2 transducers 77 hours

• Self-contained, microprocessor digital meter

- 3 transducers 51 hours

REPAIR INFORMATION

• Uses sensors and cables to remotely measure

- 4 transducers 43 hours

Bosch Service Solutions

systems under pressure

• Group weight: 2.36 kg (5.2 lb)

755 Eisenhower Drive

• Indicator has four input connectors:

Owatonna, MN 55060

• Carrying case: 394 x 311 x 102 mm (15.5 x

- Connector 1 measures pressure or vacuum

Attn: Repair Department

12.3 x 4.0 in)

Phone: 800-344-4013

- Connectors 1 and 2 measure differential

pressure

• Pressure pickup sensors:

Visit the Bosch Repair Track web link to complete and submit

the form for proper authorization:

- Connectors 2, 3, and 4 measure pressure

- 3,500, 35,000, 41,368 and 70,000 kPa (500,

https://repairtrack.bosch-automotive.com

5,000, 6,000 10,000 PSI)

• Includes Type-K thermocouple for measuring

- (198-4240 Group does not include 5,000 PSI

temperature

pressure pickup)

Specifications

NOTE: The Digital Pressure Indicator Group

• Operating temp: 0° to 38°C (32° to 100°F)

pressure sensors cannot be used with Data View

at the present time.

• Storage temp: -40° to 66°C (-40° to 150°F)

• Battery: 1U-9534 Alkaline Battery, 9 Volt

Part Number

Description

Range

Accuracy/Specification

Pressure Pickup Sensor, 500 PSI,

±0— 30 inches Hg, ±0— 100 PSI,

0.5% ±0.33 inches Hg, 0.5% ±1 PSI,

198-4237

blue connector

±0- 500 PSI, ±0— 35 bar, ±0— 3,500 kPa

0.5% ±5 PSI, 0.5% ±0.35 bar, 0.5% ±34 kPa

Pressure Pickup Sensor, 5,000 PSI,

±0— 5,000 PSI, ±0— 350 bar,

198-4238

0.5% ±50 PSI, 0.5% ±3.5 bar, 0.5% ±340 kPa

red connector

±0 - 35,000 kPa

Pressure Pickup Sensor, 6,000 PSI,

±0— 6,000 PSI, ±0— 413 bar,

198-4239

0.5% ±60 PSI, 0.5% ±4.1 bar, 0.5% ±413 kPa

orange connector

±0 - 41,368 kPa

Pressure Pickup Sensor, 10,000 PSI,

±0-10,000 PSI,±0-700bar,

251-9600

0.5% ±100 PSI, 0.5% ±7 bar, 0.5% ±700 kPa

orange connector

±0 - 70,000 kPa

8T-0458

K-Type Thermocouple Sensor

-40° to 2500°F, -40° to 1350°C

0.5% ±2 of reading, 0.5% ±2 of reading

JULY 2018 Diagnostic Tools

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Diagnostic Tools

ENGINE TOOLS

Digital Pressure Indicator Group Parts

• Used to measure vacuum, pressure,

- Connectors 2, 3, and 4 measure pressure

differential pressure, and temperature

- Includes Type-K thermocouple for

• Self-contained, microprocessor based digital

measuring temperature

meter

Reference

• Uses sensors and cables to remotely measure

• Not Shown: NEHS0818 Tool Operating

systems under pressure

Manual

• Indicator has four input connectors:

- Connectors 1 and 2 measure differential

pressure

Item

Part Number

Description

—

198-4240

Digital Pressure Indicator Group

198-4234

Indicator (face decal NEEG2932)

198-4236

Extension Cable, 20 ft (6 m) (2)

198-4229

Cable - Digital Pressure Indicator 40 ft (12 m)

198-4237

Pressure Pickup, 500 PSI (3,500 kPa), blue connector

198-4238

Pressure Pickup, 5,000 PSI (35,000 kPa), red connector (optional)

198-4239

Pressure Pickup, 6,000 PSI (41,368 kPa), orange connector

251-9600

Pressure Pickup, 10,000 PSI (70,000 kPa), orange connector

Not shown

198-4235

Foam Insert

—

6V-3072

Case - Plastic (case decal NEEG2931)

—

8T-0458

Wire - Thermocouple

Optional Items (Sold Separately)

6V-0852

Cap - Dust

—

6V-3965

Valved External Nipple, 9/16 in SAE

—

6V-3966

Valved External Nipple, 1/4 in NPT

—

6V-4144

ValvedReplacementCoupler, 1/4in NPT,internal thread

—

8T-3613

Valved External Nipple, 1/8 in NPT

1-76 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

Diesel Injection Detector

Model Usage: 3046, 3064, 3066 Engines

European Union compliant, CE marked

Reference

Warranty: Manufacturer’s

• Used to detect fuel injection pulse on diesel

• NEHS1012, Tool Operating Manual, 310-4780

engine fuel line

Diesel Injection Detector for 3046, 3064, and

3066 Engines

• Used with 9U-5358 Digital Timing Light or

other analyzer/tester with an inductive pickup

Specifications

• Pickup clamp fits around fuel line from

• Operating temperature: -18 to 50°C (-4 to

injection pump

122°F)

• 6 mm diameter pickup clamp is included with

• Storage temperature: -40 to 80°C (-40 to

6.5 mm and 1/4 inch diameter pickup clamps

176°F)

optional

• Lead length: 1.7 m (67 in)

• When afuel injection pulse is detected it

• Power requirements: 1U-9534 9 Volt Battery

causes indicator lamp to flash and sends a

current pulse through inductive loop (cable)

• Dimensions (H x L x W): 120 x 60 x 25 mm

onunit

(4.7 x 2.4 x 1.0 in)

• Inductive loop (cable) allows use of virtually

any test equipment with an inductive pickup

• Faster and more accurate than drip timing an

engine

Item

Part Number

Description

310-4780

Diesel Injection Detector

310-4777

Pickup Clamp, 6 mm diameter

—

1U-9534

Battery - 9V Size (not shown)

Optional

310-4776

Pickup Clamp, 1/4 in diameter

310-4778

Pickup Clamp, 6.5 mm diameter

Engine Harness Repair Kit

Model Usage: CT660 Truck

• Kit allows system checks to be made on

• Clip-TPA: 398-1271

running engine for real time diagnostics as

Warranty: Manufacturer’s

• Wire: 398-1297, 398-1298, 398-1299,

well as quality

398-1300, 398-1301, 398-1305, 398-1306,

• Includes 125 components

398-1307, 398-1308, 398-1309, 398-1311,

398-1312, 398-1313, 398-1314, 398-1315

• Contains all connectors and terminal pigtails

to make computer-safe repairs on engine

• Terminals: 398-1316, 398-1317, 398-1318,

electrical harness

398-1319, 398-1320, 398-1321, 398-1322,

398-1323, 398-1324

Serviceable Parts

• Backshells: 398-1325, 398-1326, 398-1332,

• Connectors: 398-1270, 398-1272, 398-1273,

398-1333

398-1274, 398-1275, 398-1276, 398-1277,

398-1278, 398-1279, 398-1280, 398-1281,

• Splice-Butts: 398-1327, 398-1328, 398-1329

398-1283, 398-1284, 398-1285, 398-1286,

• Tube-Heat Shrink: 398-1331

398-1287, 398-1288, 398-1289, 398-1291,

398-1293, 398-1294, 398-1295, 398-1296

Part Number

Description

Dimensions

Weight

372-5274

Engine Harness Repair Kit

17 x 13 x 13in

5 kg

JULY 2018 Diagnostic Tools

1-77

Diagnostic Tools

ENGINE TOOLS

Engine Harness Repair Extension Kit

Model Usage: CT660

• Two-drawer add-on kit for the existing 372-

Specifications

5274 harness repair kit for CT660s

Warranty: Manufacturer’s

• Dimensions: 102 X 305 X 458 mm (4 X 12 X

• Includes the parts necessary to repair the SCR

18 in)

harnesses

• Weight: 1.4 kg (3 lb)

Part Number

Description

467-6314

EngineHarnessRepairExtension Kit

Service/Repair Parts

467-6315

Wire Terminal - SCR Harness Repair

467-6316

Wire Terminal - SCR Harness Repair

467-6317

Wire Terminal - SCR Harness Repair

467-6318

Wire Terminal - SCR Harness Repair

467-6319

Wire Terminal - SCR Harness Repair

467-6320

Wire Terminal - SCR Harness Repair

467-6321

Wire Terminal - SCR Harness Repair

467-6322

Wire Terminal - SCR Harness Repair

467-6323

Wire Terminal - SCR Harness Repair

467-6324

Wire Terminal - SCR Harness Repair

467-6325

Wire Terminal - SCR Harness Repair

467-6326

Wire Terminal - SCR Harness Repair

467-6327

Wire Terminal - SCR Harness Repair

467-6328

Wire Terminal - SCR Harness Repair

467-6329

12 Way Connector (Tyco)

467-6330

DEF Doser Connector (SCR Harness Repair)

467-6331

Hydrocarbon Injector F Connector

467-6332

Air Shutoff Valve Connector

467-6333

Hydrocarbon Injector F Connector

467-6334

DEF Connector

467-6335

NOx Connector

467-6336

AFT Fuel Shutoff Connector

467-6337

Fuel Pressure Connector

467-6338

Female DEF Tank Level Connector

467-6339

DEFTank Heater Valve Connector

467-6340

20 Way Connector

467-6341

12 Way Connector

467-6342

DEF Connector - Female

467-6343

DEF Tank Level Connector - Male

467-6344

DEF ReturnandSuction Connector

467-6345

12 Way Connector

467-6346

Screwdriver -SCR Harness Repair

467-6347

20 Way Connector

467-6348

12 Way Connector

467-6349

DEF Connector - Male

467-6350

8 WayDPF Connector

467-6351

Lubricant Tube - SCRHarnessRepair

1-78 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

Magnetic Transducers

Model Usage: 3208

8T-5184 Transducer

8T-5185 Transducer

Warranty: Caterpillar ^®Six Months.

• 89 mm (3.5") long steel shank which is

• Has 178 mm (7.0 in) long steel shank which

12.7 mm (0.5") shorter than existing 6V-2197

is 63.5 mm (2.5 in) longer than 6V-2197

Transducer

• Can be used in applications where 6V-2197

Transducer is too long, such as on some 3208

• Can be used in applications where 6V-2197

Engines where access to top center hole in

Transducer is too short, such as on D7G SA

front cover is limited by fan belts/guards

Tractor

Part Number

Size

8T-5184

88.9 mm (3.5in) long

8T-5185

17.8 cm (7.0 in) long

Governor Test Unit Group

Model Usage: 3600 Family Engines with

• Used to test and adjust Heinzmann Electronic

References

Heinzmann Governors

Governors without running engine

• SEHS9222, Special Instruction

Warranty: Caterpillar ^®One Year

• Simplifies installation and service of governor

• SENR4661, Heinzmann Governor Service

• Measures governor frequency when engine

Manual

is running and feedback voltage when engine

Specifications

is stopped

• Frequencyrange: 100— 10,000 Hz (± 5 Hz)

• Simulates engine for following tests:

- Check governor frequency at different fuel

• Voltage range: 1 - 6 Volts (± 50 mV)

levels

• Simulator frequency: 150 - 8,000 Hz

- Adjust and check minimum and maximum

• Output voltage: 8V peak-peak maximum

governor frequency levels

- Adjust speed droop during droop operation

• Current consumption:8mAmaximum

- Check effect of gain, stability and

• Battery: 1U-9534 Battery, 9 Volt

derivative value settings on operation

• Temperature range: 0° to 45°C (32° to 104°F)

Part Number

Description

4C-6710

Governor Test Unit Group

Interface Module, Breakout Harness Assembly

Model Usage: C1.5, C2.2

• Allows technician’s laptop to communicate

with the electronically controlled governors of

Warranty: Manufacturer’s

the C1.5 and C2.2 engines

Part No.

Dimensions

446-9409

127x76.2 mm(5.0 x3.0in)

446-9410

50.8 x 254 mm (2.0 x 10.0 in)

Temperature Sensor Breakout Harness

Model Usage: CT660 Truck

• Used to measure voltage and resistance on

circuits that go to the IAT sensor

Warranty: Manufacturer’s

Part Number

Description

373-4837

Temperature Sensor Breakout Harness

JULY 2018 Diagnostic Tools

1-79

Diagnostic Tools

ENGINE TOOLS

Breakout Harness

Model Usage: 11L and 13L Engines

• Used to properly diagnose and service 11 &

Specifications

13 L engines

Warranty: Manufacturer’s

• Dimensions: 304.8 x 304.8 x 304.8 (12 x 12 x

12 in)

• Weight: 2.95 kg (6.5 lb)

Part Number

Description

372-5251

Breakout Harness

Breakout Box

Model Usage: CT660 Truck, CT11, CT13, CT15

• A multi-cable device used to test electronic

Specifications

equipment

Warranty: Manufacturer’s

• Dimensions: 381 x 304 x 76.2 mm (15 x 12 x

• Used where sufficient space or access to

3 in)

connections are not easily accessible

• Weight: 4 kg (8.8 lb)

• Allows testing of the electronic control

system components without disturbing

connections

Part Number

Description

372-5252

Breakout Box

Overlays for Breakout Box

Model Usage: CT660

• Part of the 180-pin 372-5252 Breakout Box

Warranty: None

Part No.

Description

469-0232

Chassis Overlay

469-0233

Engine Overlay

Coolant Mixer Valve Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine coolant

Specifications

valve #1, (mixing valve)

Warranty: Manufacturer’s

• Dimensions: 152.4 x 101.6 x 6.4 mm (6 x 4 x

0.25 in)

• Weight: 0.04 kg (0.08 lb)

Part No.

Description

373-4782

Coolant Mixer Valve Breakout Harness

1-80 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

Breakout Tee Kit

Model Usage: CT660 Truck

• Lead and probe test kit

Specifications

Warranty: Manufacturer’s

• Kit contains connectors necessary when

• Dimensions: 279.4 x 190.5 x 44.45 mm (11 x

testing in tight locations

7.5 x 1.75 in)

• Includes 2 tight spot test leads, over 40 spade

• Weight: .68 kg (1.5 lb)

and round terminal probes in 4 sizes, screw

banana plugs and breakout adapters

Part Number

Part Name

Description

372-5260

Breakout Tee Kit

398-4980

Female Probe

Small Gray Round Female .06 D (3 pack)

398-4981

Male Probe

Extra Large Green Male Round .11 D (2 pack)

398-4983

Female Probe

Extra Large Green Female Round .11 D (2 pack)

398-4985

Male Probe

MediumYellowMaleSpade .12 (3 pack)

398-4987

Female Probe

Medium Yellow Female Spade .12 (3 pack)

398-4988

Male Probe

Extra Small Blue Male Spade .02 x .09 (3 pack)

398-4989

Female Probe

Small Blue Female Spade .02 x .09 (3 pack)

398-4990

Female Probe

Medium Orange Female Round .075 DIA (3 pack)

398-5021

Male Probe

MediumOrangeMaleRound.075DIA(3pack)

398-5052

Female Probe

Small Purple Female Spade 1.5 x 8 mm (3 pack)

398-5056

Male Probe

Extra Small Purple Male Spade 1.5 x 8 mm (3 pack)

398-5057

Male Probe

Large White Male Spade .25 x .032 (2 pack)

398-5058

Female Probe

Large White Female Spade .25 x .03 (2 pack)

398-5059

Male Probe

Small Gray Male Round .06 DIA T.P. (3 pack)

398-5060

Male Probe

Male Terminal Square .025 Black (3 pack)

398-5061

Female Probe

Female Terminal Square .025 Black (3 pack)

398-5062

Female Probe

Female, Delphi, Terminal Spade .025 x .059 Red (3 pack)

398-5063

Male Probe

Male Terminal Spade .025 x .039 Red (3 pack)

398-5064

Male Probe

Male Terminal Round 0.03 Blue (3 pack)

398-5065

Female Probe

Female Terminal Round 0.03 Blue (3 pack)

398-5066

Male Probe

Male Terminal Round 0.039 Green (3 pack)

398-5067

Female Probe

FemaleTerminal Round 0.039Green (3pack)

398-5072

Tee Adapter

Dual Banana Plug Tee Adapter (each)

398-5080

Test Lead

Tight spot Black Test Lead (each)

398-5081

Test Lead

Tight spot Red Test Lead (each)

398-5082

Clip

Screw on Alligator clip (1 each red and black)

398-5083

Plug

Screwon Banana plug (1 each red and black)

EFP Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine fuel low

Specifications

pressure sensor

Warranty: Manufacturer’s

• Dimensions: 167.6 x 101.6 x 19.0 mm (6.06 x

4.0 x 0.75 in)

• Weight: 0.04 kg (0.08 lb)

Part No.

Description

373-4784

EFP Breakout Harness

JULY 2018 Diagnostic Tools

1-81

Diagnostic Tools

ENGINE TOOLS

Coolant Flow Valve Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine coolant

Specifications

valve #2, (flow valve)

Warranty: Manufacturer’s

• Dimensions: 167.6 x 101.6 x 19.0 mm (606 x

4.0 x 0.75 in)

• Weight: 0.04 kg (0.08 lb)

Part No.

Description

373-4783

Coolant Flow Valve Breakout Harness

EOP Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine oil

Specifications

pressure sensor

Warranty: Manufacturer’s

• Dimensions: 167.6 x 101.6 x 19.0 mm (6.06 x

4.0 x 0.75 in)

• Weight: 0.04 kg (0.08 lb)

Part No.

Description

373-4785

EOP Breakout Harness

MAT Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine charge air,

Specifications

(manifold air) temp sensor

Warranty: Manufacturer’s

• Dimensions: 167.6 x 101.6 x 19.0 mm (6.06 x

4.0 x 0.75 in)

• Weight: 0.04 kg (0.08 lb)

Part No.

Description

373-4786

MAT Breakout Harness

Exhaust Lambda Sensor & V8 EGR Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for exhaust Lambda

Specifications

sensor diagnostics

Warranty: Manufacturer’s

• Dimensions: 279.4 x 40.6 x 25.4 mm (11.0 x

1.6 x 1.0 in)

• Weight: 0.06 kg (0.14 lb)

Part No.

Description

373-4787

Exhaust Lambda Sensor & V8 EGR Breakout Harness

1-82 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

After-treatment 2 Pin Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for after-treatment

Specifications

temperature sensors and circuits

Warranty: Manufacturer’s

• Dimensions: 271.8 x 20.3 x 25.4 mm (10.7 x

• Additional diagnostics include fuel shutoff,

0.8 x 1.0 in)

fuel dump and doser circuit (for urea injection)

• Weight: 0.05 kg (0.11 lb)

Part No.

Description

373-4788

After-treatment 2 Pin Breakout Harness

EGDP Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for the exhaust gas

Specifications

delta pressure sensor

Warranty: Manufacturer’s

• Dimensions: 279.4 x 25.4 x 20.3 mm (11.0 x

1.0 x 0.8 in)

• Weight: 0.04 kg (0.1 lb)

Part No.

Description

373-4789

EGDP Breakout Harness

APS/IVS Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used on all throttle and

Specifications

sensor circuit diagnostics

Warranty: Manufacturer’s

• Dimensions: 355.6 x 31.7 x 25.4 mm (14.0 x

1.2 x 1.0 in)

• Weight: 0.07 kg (0.16 lb)

Part No.

Description

373-4791

APS/IVS Breakout Harness

Cold Weather Start Breakout Harness

Model Usage: CT660 Truck

• Used to measure voltage and resistance on

Specifications

circuits connected to Cold Start Relay (CSR)

Warranty: Manufacturer’s

• Dimensions: 203.2 x 177.8 x 50.8 mm (8 x 7

x 2 in)

• Weight: 0.3 kg (0.6 lb)

Part Number

Description

373-4744

Cold Weather Start Breakout Harness

JULY 2018 Diagnostic Tools

1-83

Diagnostic Tools

ENGINE TOOLS

Big Bore Terminal Test Probe Kit

Model Usage: CT660 Truck

• Used to access circuits in the connector

Specifications

harness and allows for use of Digital

Warranty: Manufacturer’s

• Dimensions: 111.8 x 210.8 x 43.2 mm (4.4 x

Multi-Meter without damaging the harness

8.3 x 1.7 in)

connectors

• Weight: 0.4 kg (0.9 lb)

Part Number

Description

373-4745

Big Bore Terminal Test Probe Kit

EIM Power Relay Breakout Harness

Model Usage: CT660 Truck

• Used to measure voltage and resistance on

Specifications

circuits to the EIM relay

Warranty: Manufacturer’s

• Dimensions: 254 x 203.2 x 25.4 mm (10 x 8 x

1 in)

• Weight: 0.07 kg (0.15 lb)

Part Number

Description

373-4747

EIM Power Relay Breakout Harness

ECT, EOT and EGR Control Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine coolant

temps 1 and 2, engine oil temperature sensor

Warranty: Manufacturer’s

and EGR control diagnostics.

Part Number

Description

373-4749

ECT, EOT and EGR Control Breakout Harness

CMP, CKP and FPCV Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for the engine

camshaft and crankshaft sensor diagnostics

Warranty: Manufacturer’s

and for high pressure fuel control module

(MPROP).

Part Number

Description

373-4750

CMP, CKP and FPCV Breakout Harness

1-84 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

FRP Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for the engine high

pressure fuel rail sensor

Warranty: Manufacturer’s

Part Number

Description

373-4751

FRP Breakout Harness

MAP/IAT2 Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for the engine boost

pressure and temperature (MAP/IAT2) sensor

Warranty: Manufacturer’s

Part Number

Description

373-4752

MAP/IAT2 Breakout Harness

BCS Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for the engine boost

pressure control actuator

Warranty: Manufacturer’s

Part Number

Description

373-4754

BCS Breakout Harness

EGR Position and Intake Throttle Control Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for EGR position and

intake throttle control circuit diagnostics

Warranty: Manufacturer’s

Part Number

Description

373-4778

EGR Position and Intake Throttle Control Breakout Harness

JULY 2018 Diagnostic Tools

1-85

Diagnostic Tools

ENGINE TOOLS

Retarder Control Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine retarder

valve control

Warranty: Manufacturer’s

Part Number

Description

373-4779

Retarder Control Breakout Harness

Engine Fan Control Actuator Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for engine electronic

fan control

Warranty: Manufacturer’s

Part Number

Description

373-4780

Engine Fan Control Actuator Breakout Harness

After-treatment Fuel Pressure Sensor

Model Usage: CT660 Truck

• Diagnostic harness used for engine after-

Specifications

treatment fuel pressure sensor

Warranty: Manufacturer’s

• Dimensions: 25.4 x 25.4 x 25.4 mm (1 x 1 x

1 in)

• Weight: 0.06 kg (0.14 lb)

Part Number

Description

373-4781

After-treatment Fuel Pressure Sensor

1-86 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

Breakout Harness

Model Usage: CT660 Truck

• Allows the technician to verify electrical

Specifications

voltage/signals/resistance to the ACM

Warranty: Manufacturer’s

• Dimensions: 127 X 76.2 X 304.8 mm (5 X 3 X

without probing or damaging the electrical

12 in)

connectors or the wires of the harness

• Weight: 0.23 kg (.5 lb)

Part Number

Description

455-6776

Breakout Harness

Cylinder Performance Analyzer Tool

Model Usage: CT660

• Specialized tool capable of detecting cylinder

NOTE: This tool is only compatible with

performance concerns during hot idle, cold

ServiceMaxx software on EZ-Tech computers.

Warranty: Manufacturer’s

idle, and a road test

• Detects performance concerns under any

running conditions, including intermittent

issues

Part No.

Description

Dimensions

Weight

507-8436

Cylinder Performance Analyzer Tool

254 x 457.2 x 152.4 mm (10 x 18 x 6 in)

4.536 kg (10lb)

JULY 2018 Diagnostic Tools

1-87

Diagnostic Tools

ENGINE TOOLS

Test Harness

Essential Tool

• Used for a variety of testing applications

• This sensor simulation test tool receives the

truck’s existing voltage reference (VREF) signal

Model Usage: CT660

• These are used within a test in service max

and varies it within an allowable window to

to change the readings of the DPFDP sensor

Warranty: Caterpillar ^®Six Months

simulate operating conditions.

which checks quality on the DPF truck.

• Used in conjunction with specific breakout

harnesses

Part No.

Description

Dimensions

Weight

493-2016

Test Harness

102x 153x 51mm(4x 6 x 2in)

0.23 kg (0.5 lb)

Cold Start Solenoid Test Adapter

Model Usage: CT660 Truck

• Used to properly diagnose the cold start

solenoid

Warranty: Manufacturer’s

Part Number

Description

373-4826

Cold Start Solenoid Test Adapter

Diesel Timing Adapter Group

Model Usage: 300, 1100, 3200, 3300 and 3400

• Used to check timing on diesel engines

• Group includes all items in figure

Series Engines

Part Number

Item

Description

Warranty: Caterpillar ^®One Year

8T-5301

Diesel Engine Timing Adapter Group

Parts List

6V-2198

Extension Cable

5P-7436

Adapter

5P-7437

Adapter

5P-7435

Adapter Group - Tee

6V-3016

Washer

1-88 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

Harness, 500 OHM Resistor Jumper

Model Usage: CT660 Truck

• Used for operational diagnostics of sensor

Specifications

circuits

Warranty: Manufacturer’s

• Dimensions: 127.0 x 19.0 x 19.0 mm (5.0 x

0.75 x 0.75 in)

• Weight: 0.04 kg (0.1 lb)

Part Number

Description

373-4841

500OHMResistor Jumper Harness

Harness, 3 Banana Plug

Model Usage: CT660 Truck

• Used for operational diagnostics of sensor

Specifications

circuits

Warranty: Manufacturer’s

• Dimensions: 149.9 x 129.5 x 10.2 mm (5.9 x

5.1 x 0.4 in)

• Weight: 0.06 kg (0.12 lb)

Part Number

Description

373-4842

3 Banana Plug Harness

CMP Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used for Cam position

Specifications

diagnostics on engine

Warranty: Manufacturer’s

• Dimensions: 157.5 x 94.0 x 17.8 mm (6.2 x 3.7

x 0.7 in)

• Weight: 0.04 kg (0.08 lb)

Part Number

Description

374-6405

CMP Breakout Harness

MAT Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used on the intake

Specifications

manifold temperature sensor of engine

Warranty: Manufacturer’s

• Dimensions: 157.5 x 109.2 x 22.9 mm (6.2 x

4.3 x 0.9 in)

• Weight: 0.04 kg (0.08 lb)

Part Number

Description

374-6406

MAT Breakout Harness

WIF Breakout Harness

Model Usage: CT660 Truck

• Two wire diagnostic breakout harness used

Specifications

on engine

Warranty: Manufacturer’s

• Dimensions: 320.0 x 20.3 x 20.3 mm (12.6 x

0.8 x 0.8 in)

• Weight: 0.03 kg (0.07 lb)

Part Number

Description

374-6407

WIF Breakout Harness

JULY 2018 Diagnostic Tools

1-89

Diagnostic Tools

ENGINE TOOLS

Air System Controller Breakout Harness

Model Usage: CT660 Truck

• Ten wire diagnostic breakout harness used

Specifications

on engine

Warranty: Manufacturer’s

• Dimensions: 203.2 x 165.1 x 38.1 mm (8.0 x

6.5 x 1.5 in)

• Weight: 0.1 kg (0.2 lb)

Part Number

Description

374-6408

Air System Controller Breakout Harness

Compression Brake Breakout Harness

Model Usage: CT660 Truck

• Four pin diagnostic breakout harness used on

Specifications

engine

Warranty: Manufacturer’s

• Dimensions: 152.4 x 114.3 x 25.4 mm (6.0 x

4.5 x 1.0 in)

• Weight: 0.06 kg (0.1 lb)

Part Number

Description

374-6409

Compression Brake Breakout Harness

ITR AND EGR Valve Breakout Harness

Model Usage: CT660 Truck

• Diagnostic harness used on engine throttle

Specifications

valve (ETV) and exhaust gas recirculation

Warranty: Manufacturer’s

• Dimensions: 180.3 x 114.3 x 20.3 mm (7.1 x

(EGR)

4.5 x 0.8 in)

• Weight: 0.08 kg (0.2 lb)

Part Number

Description

374-6410

ITR AND EGR Valve Breakout Harness

AFS Breakout Harness

Model Usage: CT660 Truck

• Diagnostic breakout harness used on engine

Specifications

fuel system

Warranty: Manufacturer’s

• Dimensions: 165.1 x 109.2 x 17.8 mm (6.5 x

4.3 x 0.7 in)

• Weight: 0.04 kg (0.08 lb)

Part Number

Description

374-6411

AFS Breakout Harness

1-90 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

AFT Downstream Fuel Pressure Breakout Harness

Model Usage: CT660 Truck

• Diagnostic breakout harness used on engine

Specifications

Warranty: Manufacturer’s

• Dimensions: 157.5 x 116.8 x 15.2 mm (6.2 x

4.6 x 0.6 in)

• Weight: 0.05 kg (0.10 lb)

Part Number

Description

374-6412

AFT Downstream Fuel Pressure Breakout Harness

High Pressure Fuel System Breakout Harness

Model Usage: CT660 Truck

• Diagnostic breakout harness used for

Specifications

performing diagnostics on high pressure fuel

Warranty: Manufacturer’s

• Dimensions: 381.0 x 304.8 x 19.0 mm (15.0 x

system

12.0 x 0.7 in)

• Weight: 0.10 kg (0.2 lb)

Part Number

Description

374-6415

High Pressure Fuel System Breakout Harness

SCR Breakout Harness Assemblies and DEF Test Kits

Model Usage: CT660 Trucks

• Used to provide an access point to test resistance and voltage readings while using a DVOM

(Digital Volt-Ohmmeter) during diagnostic of the supply module.

Warranty: Manufacturer’s

• Eliminates use of tee pins which could cause

damage to terminals and/or wires

Part Number

Description

Dimensions

443-4075

Supply Module Breakout Harness

457.2mm (18in)

443-4076

Tank Quality, Temp, and Level Breakout Harness

457.2mm (18in)

443-4077

Temp and Ammonia Sensor Breakout Harness

457.2mm (18in)

443-4078

Controller and Sensor Breakout Harness

457.2mm (18in)

443-4079

Backflow Line Heater Breakout Harness

457.2mm (18in)

443-4080

Pressure Line Heater Breakout Harness

457.2mm (18in)

443-4081

Suction Line Heater Breakout Harness

457.2mm (18in)

443-4082

DPF Jumper Breakout Harness

457.2mm (18in)

443-4083

Controller & Sensor Breakout Harness

457.2mm (18in)

443-7048

Ammonia Sensor Breakout Harness

457.2mm (18in)

443-7049

NH3 Breakout Harness

457.2mm (18in)

443-7050

Delta Press & GA Sensor Breakout Harness

457.2mm (18in)

443-7051

SCR Exhaust Breakout Harness

457.2mm (18in)

443-7052

DEF Interconnect Breakout Harness

457.2mm (18in)

443-7053 a

Aftermarket Injector Test Group b

304.8 x 304.8 x 152.4 mm (12 x 12 x 6 in)

443-7054 a

Def Doser Cleaning Group c

304.8 x 304.8 x 101.6 mm (12 x 12 x 4 in)

443-7055 a

DefDosingInjector Spray TestGroup d

304.8 x 304.8 x 101.6 mm (12 x 12 x 4 in)

443-7056

Pressure Gauge Adapter

50.8 mm (2 in)

a. Serviced only as a complete package.

b. Used for testing aftertreatment fuel injector located on the turbo housing for proper operation.

c. Used to protect electrical connector and diesel exhaust fluid ports during off-chassis cleaning on the outside of the diesel

exhaust fluid dosing module.

d. Includes a harness extension and hose extension to allow DEF injector to be moved to a more convenient location for testing.

Also includes 2 coolant plugs

JULY 2018 Diagnostic Tools

1-91

Diagnostic Tools

ENGINE TOOLS

Harness Assembly

Model Usage: All Machines with A5E6 Deutsch

• Used to eliminate use of spoons used for

• Eliminates damage to wire seals caused by

Connector ECM

troubleshooting ECM issues

spoons.

Warranty: Caterpillar ^®Six Months

Part Number

Description

416-1027

Harness Assembly

Detonation Sensor Harness

Model Usage: 3400, 3500, and 3600 Gas Engines

• Used to determine condition of detonation

Reference

sensor on 3400, 3500 and 3600 gas engines

Warranty: Caterpillar ^®One Year

• Page 13,May 1999, Engine News, Testing

Detonation Sensor for Proper Use

Part Number

Description

163-5443

Detonation Sensor Harness

Timing Cables

Model Usage: G3408C and G3412C Gas Engines

• Used to check ignition timing using a timing

• Cable installs between ignition wiring harness

(EIS, Electronic Ignition System)

light and flywheel markings

and valve cover connector

Warranty: Caterpillar ^®One Year

• Used to determine if a primary signal is going

• Makes timing less difficult because ignition

to each transformer

wiring is encased in ridge/flexible conduit

or in a braided wire bundle

Part Number

Use

143-4508

G3408C

143-4509

G3412C

Block Heater Power Cables

Model Usage: D9R, D10R, D11R Track-Type

• Used to supply power to the block heater on

• Used with Marinco Engine Block Heater

Tractor

large track-type tractor

connectors

Warranty: Caterpillar ^®Six Months

• Length: 15.25 m (50 ft)

• Requires customer-supplied NEMA standard

locking receptacle 125 or 250 volt outlet for

• Provides watertight seal

30 amp electrical circuit

Part Number

Description

218-7221

125 VAC, 30 A

218-7223

250 VAC, 30 A

1-92 JULY 2018 Diagnostic Tools

Diagnostic Tools

ENGINETOOLS

Spark Test Group

Model Usage: All Tier 4 Engines that require a

• In-line tool used to test for spark at diesel

• For best access, tool is double-ended to offer

higher spark capable tool

particulate filter (DPF) igniter spark plugs

a straight boot and 90° boot on one tool

Warranty: Manufacturer’s

• Designed for use with higher current levels

• Spark plug wire adapter has straight spark

than 9U-6695 Electronic Spark Plug Firing

plug boot on one end and insulator and test

Indicator

clip on other end [length: 27 cm (10.5 in)] for

testing ignition coil

• Connect the tool in-line, between spark plug

and plug wire when the engine is stopped,

tool flashes a mirror image of ignition spark

when engine is running

Part Number

Description

368-6232

Spark Tester for ARD heads on C7.1 Engines (with 370-6633 grounding lead)

370-6633

Spark Plug Wire Adapter (Grounding Lead for 368-6232 spark tester)

373-4609

Spark Test Group

Electronic Spark Plug Firing Indicator

• Greatly improved tool providing reliable way

Specifications

to diagnose ignition problems

• Diameter: 15.0 mm (0.57 in)

• Adjustable sensitivity - user can set firing

• Length: 133.4 mm (5.25 in)

indicator to flash when placed near primary

• Indicator: bright red LED

wire on exposed coils of 15.88 cm (6.25 in)

bore engines

• Battery: 3 required

• Flashing LED on top of indicator easily seen in

daylight

• Indicator can be carried easily in shirt pocket

• Once user sets sensitivity, instrument is

activated when spring clip is depressed

• Rugged plastic housing and electronic circuit

board combine durability features for a

dependable, durable instrument

Part Number

Description

9U-6695

Electronic Spark Plug Firing Indicator

JULY 2018 Diagnostic Tools

1-93

Diagnostic Tools

ENGINE TOOLS

DigitalTiming Light

• Replaces canceled 5P-6584 Timing Light

• Detachable lead set

• Inductive clamp provides fast and easy

• Works on all 12 volt systems

hookups

• 2 or 4 cycle operation

• Super bright Xenon flash tube for easier

• Light-weight and easy to handle (1.1 kg

reading of timing marks

[2.4 lb])

• Built with dependable, solid-state circuitry for

years of trouble-free service

REPAIR INFORMATION

Part Number

Description

Bosch Service Solutions

9U-5358

Digital Timing Light

755 Eisenhower Drive

Owatonna, MN 55060

Attn: Repair Department

Phone: 800-344-4013

Visit the Bosch Repair Track web link to complete and submit

the form for proper authorization:

https://repairtrack.bosch-automotive.com

1-94 JULY 2018 Diagnostic Tools

Diagnostic Tools

FLOWTOOLS

Heat Exchanger Pressure Test Tooling

Model Usage: 3516C Marine Engine

• Used to pressure test 300-5622 Heat

Reference

Exchanger

Warranty: Caterpillar ^®Six Months

• KENR6055 3500C Marine Engines

• Used with four bolts, O-ring, and 1/4 inch NPT

Disassembly and Assembly

fitting

366-3468 Cover

• Made from stainless steel to eliminate

• Overall size: 69.3 mm (2.73 in) square

corrosion

• Thickness: 6.35 mm (.25 in)

• Weight: 0.9 kg (2 lb)

366-3469 Mounting Bar

• Diameter: 50 mm (1.97 in)

• Length: 371.8 mm (14.64 in)

• Weight: 5.6 kg (12.3 lb)

Part Number

Description

366-3468

Cover

366-3469

Mounting Bar

Engine Burn Rate Meter Systems with Hand Held Display or No Display

Model Usage: 3116, 3126, 3176, 3208, 3304,

• Used to evaluate engine performance

BurnRateMeter

3406, and 3408 Engines

• Provides extremely accurate (±1% of reading)

• Uses a positive-displacement, rotary piston

Warranty: Caterpillar ^®One Year

measurement of burn rate

burn rate meter to measure burn rate and a

built-in heat exchanger to cool return fuel

• Air bubbles in return flow do not affect burn

rate readings

JULY 2018 Diagnostic Tools

1-95

Diagnostic Tools

MEASURING TOOLS

Emission Analyzer with or without Bluetooth

Warranty: Manufacturer’s

European Union Compliant, CE marked

• Integrated combustion air sensor

• Used for compliance testing and

• Trigger input

troubleshooting the combustion process

• Data memory

• Measures combustion efficiency and monitors

• DC Power Input (11-40VDC), DC Power Cable

emissions

with battery clips optional 393-0675

• Provides a multitude of field configurations for

• Carrying strap

easier set up and performance

• Bluetooth module upgrade which enables

• Offers exclusive sensor design, patented

communication between the handheld

gas paths, active sample conditioning and

controller to the analyzer box and also for the

advance data logging and reporting

analyzer box to the computer. Some countries

• Equipped to handle low thresholds and still

may have Bluetooth licensing issues. For

deliver high accuracy

those countries, the 393-0673 should be used.

• Emission Analyzer can also be used for boiler

• Power cord (shipped to match the country)

and burner testing and industrial processes

• 6 foot data connection cable

testing

• IR printer

Emission Analyzer Overview

• Thermal printer paper - 6 rolls (10 year

The 391-8170 and 393-0673 Emission Analyzers

legibility)

provide the following:

• Particle filters - pack of 30 (20 tubular filters

• Sample Gas Conditioning

for analyzer and 10 flat analyzer gas prep

• Fresh Air Valve

filters)

• Dilution System

• Pelican (or equal) Transport Case with wheels

• Data BUS capability with re-catalyst and post

• Calibration certificate (type of certificate

catalyst testing screens

country specific)

• Differential pressure sensor

• Easy Emission software with USB cord (mini

USB to standard USB)

• Type K or S temperature probe input

• Rechargeable battery

Measurement Range and Accuracy

• NO² module (0 -500 ppm, 0.1 ppm resolution):

System accuracy +/- 5% of reading

• O² Oxygen sensor (0-21%) 0.1 resolution:

(100 - 500 ppm); +/- 5 ppm (0 - 99.9 ppm)

System accuracy +/- 0.8% of full scale value

• Gas engine probe 13, 2000°F, 7 foot

• CO module (0-10,000 ppm, 1 ppm resolution,

Teflon-lined hose (8mm diameter)

H² compensated): System accuracy +/- 5% of

reading (200 - 2000 ppm); +/- 10% (2001 to

• Diesel engine probe 13, 2000°F, sintered filter,

10,000 ppm)

7 foot Teflon-lined hose (14mm diameter)

• NO module (0-3,000 ppm, 1 ppm resolution):

System accuracy +/- 5% of reading (200 -

2000 ppm); +/- 10% (2001 to 4,000 ppm)

Part Number

Description

391-8170

Emission Analyzer with Bluetooth

393-0673

Emission Analyzer without Bluetooth

JULY 2018 Diagnostic Tools

1-97

Diagnostic Tools

MEASURING TOOLS

Emission Analyzer with Bluetooth, Emission Analyzer without Bluetooth (Continued)

Control Unit Technical Data

Specifications

• Memory: 2MB (250,000 measurement value)

• Weight: 0.97 lbs

• Operating Temperature: 20°F to 115°F

• Dimensions: 10 x 4.5 x 2.3 in

• Storage Temperature: -4°F to 122°F

• Protection Class: IP 40

• Battery Type: Li-ion

• Battery Life: 5 Hours (without wireless

connection)

Specifications

• Maximum Positive Pressure Flue Gas: 20 H2O

• Maximum Negative Pressure: -120 H2O

• Dimensions: 330.2 x 127 x 436.9 mm (13 x 5

• Pump Flow Rate: 1 l/min. with flow rate

x 17.2 in)

monitoring

• Weight: 4.79 kg (10.58 lbs)

• Hose Length : Maximum 53 ft (corresp. to

• Storage Temperature: -20° to 50°C (-4° to

5 probe hose extensions)

122°F)

• Maximum Humidity Load: +158°F at gas input

• Operating Temperature: -5.5° to 45°C (22° to

of analyzer box

113°F)

• Trigger Input Voltage: 5 to 12 Volt (rising or

• Housing Material: ABS

falling flank)

• Memory: 250,000 Measurement Values

• Impulse Width >1 sec

• AC Power Supply : 90 to 260 V (47 to 65 Hz)

• Load: 5 V/maximum. 5 mA, 12 V/maximum,

• DC Voltage Supply: 11 to 40 V

40 mA

• Maximum Dust Load: 20 g/m³dust in flue gas

• Protection Class: IP40

• Dewpoint Calculation: 0° to 100°C (32 to

• Battery Life: Maximum Load Approx. 2.5 h

212°F)

Serviceable Parts

Part Number

Description

391-8171

Engine Probe Thermocouple Upgrade

391-8175

Easy Emission Software with USB Cord

391-8176

O² Replacement Sensor

391-8177

CO Replacement Sensor

391-8178

NO Replacement Sensor

391-8179

NO² Replacement Sensor

391-8180

Replacement Filter for NO Sensor

391-8181

Particle Filter

393-0675

DCPowerCable with Battery Clamps

393-0676

Battery for Base Unit

393-0677

Gas Engine Probe 8 mm

393-0678

Diesel Engine Probe 14 mm

393-0679

6 Foot Data Cable

393-0681

ThermalPaper6 Roll

NOTE: Additional options are available from the manufacturer

Countries Licensed for Bluetooth:

Contact Information

Europe including all EU member states

European countries (EFTA)

USA and International:

• Austria, Belgium, Bulgaria, Cyprus, Czech

• Iceland, Liechtenstein, Norway and

http://www.testo350.com/contact.html

Republic, Denmark, Estonia, Finland, France,

Switzerland

Germany, Great Britain, Greece, Hungary,

Non-European countries

Ireland, Italy, Latvia, Lithuania, Luxembourg,

Malta, Netherlands, Poland, Portugal,

• Canada, USA, Japan, Ukraine, Australia,

Romania, Slovakia, Slovenia, Spain, Sweden

Colombia, El Salvador, Venezuela

and Turkey

1-96 JULY 2018 Diagnostic Tools

1-96

Diagnostic Tools

MEASURING TOOLS

Extended Collet

Model Usage: 3500 Family Engines

• Improves accuracy of fuel setting

• Has been added to 6V-7880 Timing and Fuel

measurement and adjustment on the 3500

Setting Tool Group

Warranty: Caterpillar ^®Six Months (Not

Engine

repairable)

• Fits all dial indicators with 9.5 mm (0.375 in)

• Used with 8T-1002 Electronic Position

mounting boss

Indicator Probe or dial indicator

• 82.6 mm long; 3/8-16 thread for mounting on

• Prevents side loading of probe shaft by fuel

engine

stop lever in governor; side loading can cause

• Allows 25.4 mm (1.0 in) probe travel when

setting errors and breakage of contact point

used with 76.2 mm (3 in) shaft extension

on indicator

Reference

• Attaches to indicator probe or dial indicator;

is correct length for 5P-7263 Contact Point

• SEHS9278, Special Instruction

specified in 3500 fuel testing and adjusting

instructions

Part Number

Description

4C-8753

Extended Collet

JULY 2018 Diagnostic Tools

1-99

Diagnostic Tools

MEASURING TOOLS

Dial Indicator Test Group

Warranty: Caterpillar ^®Six Months

• Provides tooling used in taking many

• Magnetic base provides easier and quicker

different service measurements such as gear

mounting of the dial indicator; the former

backlash, end clearance, side clearance, valve

7H-1949 Dial Indicator Test Group can be

movement or rack position

updated by adding the 8S-2329 Base and the

8S-2327 Post

• Contains all components of the 7H-1949 Dial

Indicator Group, along with an 8S-2329 Base

and 8S-2327 Post

Item

Part Number

Description

—

8T-5096

DialIndicator Test

2P-8311

Block

6V-3072

Case - Plastic, NEEG2574 Group Decal on lid

7H-1946

Arm

7H-1942

Indicator

8S-2329

Base

7H-1940

Universal Attachment

7H-1947

Holder

8S-2327

Post

7H-1945

Holding Rod

7H-1645

Holding Rod

7H-1943

Clamp

7H-1948

Snug

Dial Indicator Group

Warranty: Caterpillar ^®Six Months

• Used primarily for measuring off-engine

• Can also be used in other applications for

timing dimensions when setting fuel pump

accurate depth measurements up to 127 mm

lifters

(5 in)

• Measurements made with a 25.4 mm (1.0 in)

travel indicator and 5 contact points

Item

Part Number

Description

—

6V-7926

Indicator Group

6V-3073

Case - Plastic

6V-7029

Block-Top

6V-7924

Holder Block

8S-3158

Indicator

3P-1565

Collet Clamp

5P-4156

Base

5P-4163

Point— Indicator Contact, 120.65 mm (4.75 in)long

5P-4162

Contact Point

5P-4161

Point - Indicator Contact, 69.85 mm (2.75 in) long

3S-3270

Point - Indicator Contact, 44.45 mm (1.75 in) long

5P-4160

Point - Indicator Contact, 19.05 mm (0.75 in) long

5P-4159

Gauge Stand

5P-4158

Gauge, Fuel Inj 50.8 mm (2 in)

5P-4157

Gauge, Fuel Inj 101.6 mm (4 in)

1-98 JULY 2018 Diagnostic Tools

Diagnostic Tools

MEASURING TOOLS

Indicator Base

Essential Tool

• Used to measure installation height of

Specifications

Duo-Cone seals

Model Usage: All Models Containing Duo-Cone

• Overall length: 127 mm (5.0 in)

Seals

• Used with 6V-3075 Dial Indicator, 6V-6167

• Length from centerline of indicator to outer

Contact Point, and 3P-1565 Indicator Collet

Warranty: Caterpillar ^®Six Months

edge: 122 mm (4.8 in)

• Made of plastic to prevent damage to sealing

• Width: 15 mm (0.6 in)

surface of seal ring

•

Threaded hole: 3/8 - 32 thd

• Extra long base provides stability when

• Material: Plastic

measuring installation height

Item

Part Number

Description

165-8958

Indicator Base

Additional tooling required

6V-3075

Indicator - Dial

3P-1565

Collet Clamp

Not Shown

6V-6167

Contact Point

Soft Tool Case

Model Usage: All Models

• Low-costprotection for discontinued 1U-9800

• Quick-close top uses Velcro to permit quick

Ultrasonic Wear Indicator

removal of instrument

Warranty: Caterpillar ^®One Year

• Resistant to oil, fuel, and coolant

Specifications

• Adjustable neck strap for hands-free

• Dimensions: 195 x 195 x 40 mm (7.25 x 7.25

operation

x 1.75 in)

• Encased keyboard and display

• Weight: 227 g (0.5 lb)

Part Number

Description

9U-6175

Soft Protective Case

Custom Track Service (CTS) Tool Group (423-0478)

No.

Part Number

Description

415-4055

Ultrasonic Indicator IV Group

8H-8580

Scraper

5P-3920

12" Steel Ruler

4S-9405

12" Caliper

5P-3277

12" Tape Measure

423-0483

Depth Gauge

505-8671

Ultrasonic Couplant x 2

Ultrasonic Probe

Model Usage: 6015, 6015B, 6018, 6020B, 6030,

• 12.7 mm (1/2 in) diameter dual element probe

Specifications

6030B, 6040, 6050, 6060 6090, 7295, 7495

is ideal for measuring thickness in larger

• Dimensions: 19 x 31.5 x 1270 mm (0.75 x 1.25

undercarriage components

Warranty: Caterpillar ^®One Year

x 50 in)

• Used with 415-4051 Ultrasonic Wear Indicator

• Weight: 0.1 kg (0.22 lb)

• Frequency: 5 MHZ

Part Number

Description

461-0303

Ultrasonic Probe

JULY 2018 Diagnostic Tools

1-101

Diagnostic Tools

MEASURING TOOLS

Ultrasonic Wear Indicator IV Group, Dakota Ultrasonics

Model Usage: Dozers, Excavators, Trucks (beds),

European Union Compliant, CE marked

• Stores measurements from 100 machines

Track Loaders

• Used to quickly and accurately measure track-

• Measurement accuracy 0.1 mm (.01 in)

Warranty: Caterpillar ^®One Year

type machine undercarriage wear

• Reduced part cleaning and measurement

• Also can be used to accurately measure steel

storage saves time

part thickness without changing any settings

• Readings stored in memory are transferable to

• Easy battery access - (unscrew calibration

computer for printing

disk at top of Indicator IV)

• Use with 545-8721 VersaSonic High-

• Uses 3 Alkaline or rechargeable AA batteries

Temperature, High-Viscosity Ultrasonic

(no battery pack)

Couplant

• Larger graphical backlit liquid crystal display

Reference

• Power level monitor indicates remaining

• NEHS1164, Tool Operating Manual

battery power

Specifications

• Built-in multiple language capability (English,

• Operating Temperature: -10° to 60°C (-14° to

French, German, Portuguese, and Spanish) -

140°F)

no program modules or reflashing needed to

switch language

Storage Temperature

• 415-4055 includes updated probe with thinner

• Without Batteries Installed: -40° to 60°C

housing for easier access in tight spaces

(-40° to 140°F)

• Used with Custom Track Service (CTS)

• With Alkaline batteries less than 6 months:

inspections, which can be downloaded

-40° to 50°C (-40° to 125°F)

directly to a computer for viewing or printing

With NiCad batteries less than 6 months: -20°

•

• Recalls and shows last machine or location

to 45°C (-4° to 113°F)

display screen used when turned on

Weights

• 415-4055: 3 kg (6.75 lb)

• 415-4051: .4 kg (0.84 lb)

• 415-4052: .113 kg (.25 lb)

Ultrasonic Wear Indicator IV Group (415-4055)

Repair Information: Must Call for RMA# before

Item

Part Number

Description

sending. Dakota Ultrasonics, 1500 Green Hills

415-4051

Ultrasonic Indicator IV

Rd. #107, Scotts Valley, CA 95066,

415-4052

Ultrasonic Probe

Ph: 831 431 9722, Fax: 831 431 9723

415-4053

Soft Case

415-4054

Foam

425-6888 (Part of 415-4051 Group)

Lemo to Serial Cable

To request an RMA#:

267-6532

Towel x 18

Lela Virgallito - lela@dakotainst.com

6V-7145

Case

Kris Stevens - kris@dakotainst.com

NEHS1164

Tool Operating Manual

Andrea McCarrick - andrea@dakotainst.com

Technical Support:

Rich Engel - rich@dakotainst.com

Will Holt - will@dakotainst.com

UltrasonicWear Indicator IV (415-4051)

Part Number

Description

Also includes:

USB to Serial Adapter

—

Rubber Lemo plugs x 4

NEHS1164

Tool Operating Manual

425-4688

Lemo to Serial Cable

1-100 JULY 2018 Diagnostic Tools

Diagnostic Tools

MEASURING TOOLS

Service Repair and Optional Parts for Ultrasonic Wear Indicator IV

Part Number

Description

1U-7445

Nicad Battery, rechargeable, package qty 1 (5 required to power Indicator III)

1U-9533

AA Alkaline Battery, non-rechargeable, package qty 96 (5 required to power Indicator III)

4C-5490

Couplant Holder

4C-5488

Cable Assembly RS232 - to transfer thickness values to the CTS programin a PC AT version

4C-5489

Cable Assembly RS232 - to transfer thickness values to the CTS program in a PC XT version

4C-5897

Modem Cable

9U-6175

Soft Protective Case

Ultrasonic Couplant, Cat^®

Warranty: Caterpillar ^®Six Months

• Required for use with Cat Ultrasonic Wear

• High viscosity, no-drip formula

Indicator IV and the Intrinsically Safe

• Operating ranges 10 to 220 degrees F (-12 to

Ultrasonic Thickness Gauges

104 degrees celcius)

• 94 ml (3.2 fl-oz)

Part Number

Description

505-8671

Cat^®Ultrasonic Couplant

Ultrasonic Couplant, VersaSonic High-Temperature, High-Viscosity

Warranty: Manufacturer’s 5-Year Shelf Life and

• An ultrasonic couplant for harsh conditions

• Superior, long-term corrosion inhibition

Performance. Contact 360-671-9121

including rain, snow, mud and all temps

• Compatible with plastics

or sales@echoultrasonics.com.

• 4 oz, biodegradable

• For use with Cat^®Ultrasonic Wear Indicator

• Operating Range: -10 to 750°F /-23 to 398°C

IV and Intrinsically Safe Ultrasonic Thickness

Gauges

Part No.

Description

Weight

VersaSonic High-Temperature, High-Viscosity Ultrasonic

545-8721

0.23 kg (0.5 lb)

Couplant

Bolt Tension Test Group

Model Usage: G3600, 3600, and C280 Engines

European Union Compliant, CE marked

• Includes (reader head, signal processor,

equipped with Ultrasonic Connecting Rod Bolts

battery charger, temperature sensor, Ethernet

• Includes 438-3353 bolt torque controller and

cable, case, instructions and software CD

Warranty: Caterpillar ^®One Year

438-3355 bolt torque sensor

• Requires a PC (laptop) for complete function

• Replaces Intellifast Load Probe (LP) 3000

• Connects to PC via Ethernet cable or WIFI

• Used to measure the tension applied to

connecting rod bolts that utilize integrated

• Contains a rechargeable Lithium Polymer

ultrasonic sensors

battery

• Ensures correct tension has been achieved

Specifications

during the torque process

• Dimensions: 410 x 170 x 330 mm (16.14 x 6.69

• Battery powered and portable

x 12.99 in)

• Power: 100-240 Volt 50/60 Hz

Part Number

Description

438-3338

Bolt Tension Test Group

456-6619

Inspection Head Lens with Instructions

456-6620

Inspection Head Bolt Sleeve

456-6621

Inspection HeadwithCables

456-6622

Control Module with Battery

456-6623

Temperature Probe with Cable

1-102 JULY 2018 Diagnostic Tools

Diagnostic Tools

MEASURING TOOLS

Differential Pressure Gauge, Carrying Case Group

Essential Tool

• Used to measure low air pressure and/or non-

Tips for Obtaining Accurate Pressurization

corrosive gas pressure

Readings

Warranty: Caterpillar ^®Six Months

• Frictionless magnahelic movement

• Route gauge pickup tube under door seal into

cab

• Positive, negative, and differential readings

• Do not crush pickup tube between door seal

• No manometer fluid to evaporate or freeze

and cab frame

• Does not have to be level

• Make sure pickup tube is completely sealed (if

• Used with 199-9817 Carrying Case Group

door seal collapses it can cause air leaks)

which includes carrying case, mounting

• If complete seal cannot be achieved, replace

bracket, and 3 m (9 ft) of 4.76 mm (3/16 in) ID

door seal

rubber tubing

• Insert pickup tube in approximate area of

Cab Pressurization Testing

operators head and chest

• Used to measure cab pressurization standards

199-6268 Differential Pressure Gauge

• Minimizes dust and noise in cab by making

• Vacuum: 0 - 25.4 mm (0 - 1 in) of water

sure a positive pressure of 5.08 to 15.24 mm

(0.2 to 0.6 in) of water is maintained

• High and low-pressure connections: 1/8 NPT

• Helps air conditioning system to operate at

• Accuracy: ±2% of full scale

maximum efficiency

Part Number

Description

199-6268

Differential Pressure Gauge

199-9817

Carrying Case

Multiple Anvil Micrometer, Adapter

Warranty: Caterpillar ^®Six Months

• Micrometer used for measuring top flange

• When measuring engine valve lips with

thickness on cylinder liners, and also with

the 6V-2034 Adapter, refer to the valve

the 6V-2034 Adapter to measure Cat^®engine

dimensions given in the Guideline for

valve lip thickness

Reusable Parts, Form SEBF8034

• Furnished with 2 anvils - 1 anvil is for

measuring parts which can not be measured

with a standard micrometer; the other to be

used as a general purpose 0 to 25 mm (0 to

0.98 in) measuring instrument

Part Number

Description

6V-2034

Adapter

6V-7059

Multiple Anvil Micrometer

1-104 JULY 2018 Diagnostic Tools

Diagnostic Tools

MEASURING TOOLS

Ring Gage Assembly

Model Usage: 3500-Series Engines

• Used to accurately measure valve lip

• Comes with removeable centering bushings

thickness on 70 degree angle 3500-series

to measure valves with 9.4 mm or 11.0 mm

Warranty: Caterpillar ^®Six Months

valves

stems

• Can be used with an indicator and base, depth

Reference

micrometer, feeler gage or precision gage

• M0088789 Tool Operating Manual 550-9152

blocks

Ring Gage Assembly

• Eliminates measuring errors by locating the

• SEBF8155 Reuse and Salvage Guidelines

measuring surface on the factory-established

(Specifications for Cylinder Head Assemblies

gage point

for 3500-Series Engines)

Part No.

Description

Dimensions

Weight

550-9152

Ring Gage Assembly

76 Dia x 38 mm (3 Dia x 1.5 in)

0.5 kg (1 lb)

Gauge Group, Micrometer Depth (in), Gauge Group, Micrometer Depth (mm)

Warranty: Caterpillar ^®Six Months

• Contains a complete set of measuring rods

• Base: 76.2 mm (3.00 in) wide; uses 3.96 mm

from 0 to 228.6 mm (0 to 9 in) which are all

(5/32 in) rods

stored in the wooden case

Item

Part Number

Description

Case (Not available)

6V-0088

Rod, 177.8 - 203.2 mm (7 - 8in)

6V-0091

Rod, 203.2 - 228.6 mm (8 - 9in)

Not Shown

316-1188

Rod,228.6- 254mm (9— 10in) sold separately

—

6V-2012

Gauge Group

—

6V-7030

Gauge Group

JULY 2018 Diagnostic Tools

1-103

MEASURING TOOLS

Micrometer

Warranty: Manufacturer’s

• Measures small thicknesses or diameters

• Two 3-volt batteries included

• Balanced frame for comfort and accuracy

• Automatic OFF

• IP67 protection against coolants, water, chips,

• Measurement HOLD button

dust and dirt

• Inch/millimeter metric conversion provides

• No-glare satin chrome finish

simple, universal, standardized unit of

measurement at any position

• Hard and stable one piece fiction thimble

permits one-hand operation and uniform

• Resolution .00005 in (0.001 mm)

contact pressure

• Accuracies (±.0001 in (±.002 mm)

• Spindle lock

• Measuring Capacities 1 in (25 mm)

• Ability to zero tool at any position and

* Does not have RS232 digital output

retain and return to true zero reading of the

micrometer

Specifications

• Micro-lapped carbide measuring faces

26.9 x 57.9 x 148 mm (1.1 x 2.3 x 5.8 in)

Part Number

Description

431-4150

Micrometer

Inside Micrometers

Warranty: Manufacturer’s

• Light, easy to use: great for inside diameters

Specifications

of cylinders and rings and parallel surfaces

473-8688 and 473-8689

• Micrometer Type Inside Micrometer Set

• Insulated rods marked with length

• Range - See Chart

• Measuring rods are solid and assembled on

• Graduations (in) .001”

one side of the micrometer head

• Measuring Rods - See Chart

• Hardened and ground anvils on rods,

• Spacing Collars - See Chart

adjustable for length.

• Case Type - See Chart

• Quick-reading figures - every thousandth

474-3709 and 474-3710

number on inch reading tools

• Accuracy (in) Lead accuracy +/-.0001” per inch

Screw

Measuring

Part Number

Range

Spacing Collars

Case

Movement

Rods

473-8688

2-12 in

0.5in

0.5 in (qty 1)

Padded

473-8689

50-300 mm

13 mm

12 mm (qty 1)

Padded

474-3709

8-32 in

1.0in

1.0 in (qty 1) 2.0 in (qty 2)

Wood

474-3710

200-800 mm

25 mm

25 mm (qty1) 50 mm (qty2)

Wood

Tool Pressure Monitor,Tool Initiator

Model Usage: Off-Highway Trucks equipped with

European Union Compliant

389-7005

Tire Monitoring Kits

• Used to allow maintenance personnel to

• Handheld device designed to provoke data

Warranty: Caterpillar ^®One Year

wirelessly 'ping' a tire to measure its real-

transmissions from tire sensors

time tire pressure

• The tool can be used to assist installer during

• Improves inflation accuracy and reduces

new installations, sensor replacement, and

diagnostic time

installation verification

• Tools are shipped with supplier tool operating

389-7004

manuals

• Handheld 125 kHz LF Generator, RS-232

• Shipped with uninstalled batteries

Diagnostic Interface Port, Receiver Bandwidth

400 kHz

Part No.

Dimensions

Weight

389-7004

230 x110 x 20 mm (9 x 4.5 x 0.8 in)

1.5 kg (3.15 lb)

389-7004

389-7005

190 x120 x 20 mm (7.5 x 4.7 x 0.8 in)

0.227 kg (.6125lb)

JULY 2018 Diagnostic Tools

1-105

Diagnostic Tools

MEASURING TOOLS

Outside Micrometers

Warranty: Manufacturer's

• Balanced frame and thimble design ensure

• Ability to zero tool at any position as well as

easy handling and better readability

retain and return to the true zero reading of

the micrometer

• Compatible with Wireless Data Collection

Systems

• Ring-type knurled lock nut for quick and sure

locking

• Advanced sleeve design with staggered lines

and distinct figures for precise and easy

Specifications

readability

• Micrometer Type Electronic Interchangeable

• Conventional inch or millimeter graduations

Anvil OutsideMicrometer

standard

• Range - See Chart

• Quick and easy adjustment

• Resolution - See Chart

• Large, easy-to-read, high-contrast LCD digital

• Anvil/Spindle Material Steel

readout

• Anvil Type Flat

• No-glare satin chrome finish on thimble and

sleeve minimizes annoying surface glare

• Spindle Type Flat

under bright lights indoors or filters out UV

• Lock Nut Type Knurled Ring Type

light

Thimble Type Friction

•

• No-glare black wrinkle finish on frame

SPC Output SPC Output

•

• Hard and stable one-piece friction thimble

• Case Type: Wood

permits one-hand operation of micrometer

and uniform contact pressure

• Rigid and stable special cast iron frame with

appropriate perforations for lightness and

ribbed for strength and stability

Part Number

Range (in)

Range (mm)

Resolution (in)

Resolution (mm)

473-8690

0-4

0-101

0.00005

0.001

473-8691

2-6

51-152

0.0001

0.001

473-8692

6-12

152-305

0.0001

0.001

Telescoping Gauge

Warranty: Manufacturer’s

• Precision Ground Radius on each gauge

• Ends of both contacts are hardened and

provides two-point contact for maximum

ground to a radius to allow proper clearance

accuracy

on the smallest hole the gage will enter

• Soft Case included

Specifications

• Handles can be individually ordered and/

• Range (in) 1/2 - 6”

or ordered in larger sizes such as 8”, 12” or

• Range (mm) 13-150 mm

longer

• Handle Length (in) 2-3/8 - 3-1/4”

• Features a handle, one rigid contact arm and

one spring-tensioned telescoping contact arm

• Handle Length (mm) 60-82 mm

Part Number

Description

473-8687

Telescoping Gauge

JULY 2018 Diagnostic Tools

1-107

Diagnostic Tools

MEASURING TOOLS

Point Group

Warranty: Caterpillar ^®Six Months

• Has more contact points for the dial indicators

• These contact points will fit all dial indicators

with 4 to 48 threads but will not fit the 1P-

• Has straight contact points from 2.18 to

2103 Dial Indicator

120.5 mm (0.09 to 4.74 in) long, 3 flat points,

and a 12.7 mm (0.50 in) extension

• Comes with 6V-2030 Indicator Extension

• Has a plastic box with a divided tool holder

and space to cut more slots for storage of

special points (part numbers and sizes are

shown on a chart inside the lid of the box

ContactPoints (Included in 6V-6042)

Part Number

Size

3S-3268

6.4mm (0.250in)

3S-3269

25.4mm (1.00in)

3S-3270

44.5mm (1.75in)

5P-2393

38.1mm (1.50in)

5P-4160

19.1mm (0.75in)

5P-4161

69.9mm (2.75in)

5P-4162

95.3mm (3.75in)

5P-4163

120.5 mm (4.75 in)

5P-4809

50.8mm (2.00in)

5P-6531

57.2mm (2.25in)

5P-7261

31.8mm (1.25in)

5P-7262

63.5mm (2.50in)

5P-7263

76.2mm (3.00in)

5S-8086

2.4 mm (0.094 in) a

6V-2057

3.2 mm (0.125 in) b

8S-3675

3.1mm (0.122in)

9S-0229

9.7mm (0.38in)

9S-8883

12.7mm (0.50in)

9S-8903

2.4 mm (0.094 in) a

Additional Contact Points Available (Sold Separately)

5P-2057

Contact Point

1P-5512

Contact Point

6V-6167

Contact Point

1P-5513

Contact Point

5P-2056

Contact Point

Service/Repair Parts (Sold Separately)

Not Shown

6V-6043

Block Holder

Not Shown

6V-6045

Case - Plastic, NEEG2061 Accessories Case Decal

a. 6.4 mm (0.25 in) diameter flat face

b. 9.52 mm (0.375 in) diameter flat face

c. 12.7 mm (0.5 in) diameter flat face with a bevel to 9.7 mm (0.38 in) diameter

Dial Bore Gauge Group

Warranty: Caterpillar ^®Six Months

• Gauge and related masters provide accuracy

• Particularly useful for measuring the relief

to 0.0025 mm (0.0001 in) for measuring all

valve spool bores in pressure control bodies

bores in the size range 19.05 - 38.10 mm

on 631, 633, 637, 641, 650, 651, 657, 660, and

(0.750— 1.500 in)

666 Tractors with eight speed transmissions

Item

Part Number

Description

5P-2170

Dial Bore Gauge Group

Master Gauges (available separately)

5P-2043

Gauge, 19.050 mm (0.7500 in)

5P-2059

Gauge, 22.225 mm (0.8750 in)

5P-2171

Gauge, 27.051 mm (1.0625 in)

5P-2172

Gauge, 28.575 mm (1.1250 in)

5P-2174

Gauge, 38.100 mm (1.5000 in)

1-108 JULY 2018 Diagnostic Tools

Diagnostic Tools

MEASURING TOOLS

Dial Bore Gauge Group for Inch Measurements

Warranty: Caterpillar ^®Six Months

• Specifically, they should be used when

• Useful for making any critical bore

reconditioning the cylinder bores on 1100 and

measurement from 50.8 to 203.2 mm (2.0 to

3100 Series Engines and when refinishing

8.0 in)

connecting rods in 137.16 mm (5.4 in) bore V8

Reference

and V12 Engines

• GMGO0981, Special Instruction

Item

Part Number

Description

—

1P-3537

Dial Bore Gauge, Inch Measurements

9U-6615

Size Setting Fixture Group

1P-3535

Dial Bore Gauge

Battery and Coolant Refractometer

Model Usage: All

European Union compliant, CE marked

• Carrying case and calibration screwdriver

Warranty: Caterpillar ^®One Year

• Used to measures freezing point of coolants

• Reads degrees Centigrade and Fahrenheit

plus battery charge condition

Specifications

• Refractometer uses a prism and lens with

• Range: Resolution

simple focus adjustment to provide accurate

and repeatable measurements on easy to read

• -60° to 32°F propylene glycol freeze point:

10°F

• Automatic temperature compensation (ATC)

• -50° to 0°C ethylene glycol freeze point: 5°C

• Requires only 2 or 3 drops of solution

• 1.15 to 1.3 specific gravity of battery acid: .01

Part Number

Description

245-5829

Coolant Test Kit

Fractional Digital Caliper, 6 Inch

Model Usage: All machines/models

European Union Compliant, CE Marked

Specifications

Warranty: Caterpillar ^®One Year

• For inside, outside depth and step

• Range: 0 - 6 in (0 - 150 mm)

measurements

• Resolution: 0.0005 in (0.01 m or 1/64 in)

• Tri-mode digital display; Inches, Millimeters,

• Accuracy: 0.001 in (± 0.02 mm)

and Fractions

Length: 38 mm (1.5 in)

•

• Auto off

Width: 114 mm (4.5 in)

•

• Replacement Battery; LR44

• Depth: 292 mm (11.5 in)

• Construction: Carbon Fiber

• Weight: 289.4 gram (0.638 lb)

Part Number

Description

367-9109

6" Fractional Digital Caliper

1-110 JULY 2018 Diagnostic Tools

Diagnostic Tools

MEASURING TOOLS

Dial Bore Gauges

Warranty: Caterpillar ^®Six Months

• Used for precision metric measurements

• 6V-7897 Dial Indicator is available to convert

the current 1P-3535 Dial Bore Gauge to the

• Measure all internal diameters from 50 to

6V-7898 Dial Bore Gauge (all 1P-3535 Gauges

200 mm (1.97 to 7.87 in) and depths from 13

can be converted except earlier gauges

to 300 mm (0.51 to 11.81 in) in increments of

marked “MADE IN ENGLAND”)

0.002 mm (0.00008 in)

• Increased accuracy is needed for applications

References

such as connecting rods where the tolerances

• SMHS8253, Special Instruction, instructions

are very small

for use of the 6V-7898 Dial Bore Gauge and

• Use of the gauge is simplified because all

also information for converting the 1P-3535

current specifications are given in metric

Gauge to the 6V-7898 Gauge

dimensions

• SMHS8254, Special Instruction, instructions

for use of the 6V-7899 Size Setting Fixture

Part Number

Description

1P-3535

Dial Bore Gauge

6V-7897

Dial Indicator for Converting 1P-3535 Dial Bore Gauge to Metric

6V-7898

Dial Bore Gauge, Metric

6V-7899

Size Setting Fixture, Metric

Dial Bore Gauge and Master Rings

Model Usage: 3600 Engines, Gas and Diesel

147-8860 Master Ring (diesel 280.025 mm

147-8861 Master Ring (gas 300.00 mm

[11.0246 in])

[11.811 in])

Warranty: Caterpillar ^®Six Months

• Used to calibrate dial bore gauge to

280.025 mm (11.0246 in)

300.000 mm (11.811 in)

• Calibrates gauge for use on diesel engines

• Calibrates gauge for use on gas engines

147-8862 Dial Bore Gauge

• Used to measure 3600 Engine cylinder liners

• Dial graduated to 0.002 mm

• Tool can reach up to 457 mm (18.0 in)

Part Number

Description

147-8860

Master Ring (diesel 280.025 mm [11.0246 in])

147-8861

Master Ring (gas 300.00 mm [11.811 in])

147-8862

Dial Bore Gauge

Dial Bore Gauge for Metric Measurements, Size Setting Fixture

Warranty: Caterpillar ^®Six Months

6V-6030

• Will set or check the dial bore gauge in

0.002 mm (0.00008 in) increments within its

• Precision measuring instrument with a

range of 0 to 50 mm (0 to 1.97 in)

diameter range of 30.0 to 50.8 mm (1.2 to

2 in) graduated in 0.002 mm (0.00008 in)

• Fixture has a magnifying glass for easier

increments

reading

• Depth range: 8.5 to 150 mm (0.335 to 5.91 in)

References

• Gauge is especially useful for measuring

• SMHS8037, Special Instruction for 6V-6000

piston pin bores for 3300 Series Engines

• SMHS8036, Special Instruction for 6V-6030

Part Number

Description

6V-6000

Dial Bore Gauge for Metric Measurements

6V-6030

Size Setting Fixture

JULY 2018 Diagnostic Tools

1-109

Diagnostic Tools

MEASURING TOOLS

Vernier Caliper (Gear Tooth Measurement)

Model Usage: 7495

• Used to measure the swing gear assembly

Specifications

tooth wear in three locations on the swing

Warranty: Manufacturer’s

• Dimensions: 107.95 x 97.23 mm (4.25 x

gear tooth

3.82 in)

• Specialized vernier caliper equipped with a

dual slide caliper to measure tooth thickness

Part Number

Description

447-2460

VernierCaliper (Gear ToothMeasurement)

Surface Plate

Warranty: Caterpillar ^®Six Months

• Use for checking small shafts and bars for

• Plate measurements: 304.8 x 330.2 x 38.1 mm

straightness; checking flat surfaces for warp;

(12.0 x 13.0 x 1.5 in)

and trimming rings, bearing caps, etc., using

NOTE: As this plate is meant for general shop

fine emery cloth

use, its surface is ground but not spot-scraped.

Part Number

Description

7B-0337

Surface Plate

Profilometer

Model Usage: All

• Used to measure the surface finish of

• 448-3697 is equipped with Bluetooth feature

machined parts, including hydraulic cylinder

and includes a hand held evaluation unit

Warranty: Manufacturer’s

rods, liners, cylinder bores, machined gear

• 448-3698 is only the drive unit and does not

bushings, and crankshaft journals

haveBluetooth feature

• Includes base unit, drive unit, built-in

• Optional accessory right angle adapter

battery, roughness standard integrated into

507-2251 used with 448-3698 to measure

casing, height adjustment accessory, pick-up

crackshaft journals axially

protection, charger/mains adapter, operating

instructions, carrying case, and USB cable

Part Number

Dimensions

Weight

448-3697

190 x 140 x 75 mm (7.48 x 5.51 x 2.95 in)

1 kg (2.20 lb)

448-3698

140 x 50 x 70 mm (5.51 x 1.97 x 2.76 in)

0.4 kg (0.88 lb)

Surface Roughness Standard

Model Usage: All

• Used to verify the accuracy of the 448-3697

• Plastic construction

and 448-3698 profilometers

Warranty: Manufacturer's

• 3.0 x 3.0 in (76.2 x 76.2 mm)

• Roughness Average in Microinch and

Micrometer- (121 +/- 2 ; 3.07 +/- 0.05

Part Number

Description

453-5376

Surface Roughness Standard

1-110 JULY 2018 Diagnostic Tools

Diagnostic Tools

PAVING PRODUCTS

Cable Assembly, Software

Model Usage: AP255E, AP300D

• Used to provide a convenient and user-friendly

Specifications

method of executing service functions for

Warranty: Caterpillar ^®One Year

• Overall Length: 3.0 m (10.0 ft)

Bodas controllers from Rexroth used on small

• Weight: 0.3 kg (0.7 lb)

pavers

Part Number

Description

436-3873

Cable Assemlby

436-3874

Software

Electrical Displacement Control Test Box

Model Usage: AP-800 (1BF), AP-1200 (2JD)

• Tests electrical displacement control (EDC) in

If the machine moves, the problem is electrical.

Asphalt Pavers; RR-250 (6ED) Road Reclaimers;

Sundstrand hydraulic systems (ground drive

Proceed with the following checks. If the

SS-250 (6DD) Soil Stabilizers

pump)

machine does not move, the problem is in the

hydraulic system and further electrical checks

Warranty: None

• Will move machine if electrical system failure

are not necessary

other than EDC

Ensure proper polarity when connecting

• Minimum-maximum resistance: 0 - 250 ohms

large battery clips (7, 8) to the battery.

For asphalt paving machines only, if an electrical

Turnthe potentiometer (1) to the maximum

failure causes the brakes to be engaged, use a

resistance position (250 ohms).

jumper wire to supply electrical power directly

to the brake solenoid. If the brake solenoid has

Connect the mini-clips (9) to the EDC wiring

failed, use a portable hydraulic power supply to

harness.

release the brakes when the machine is to be

Slowly turn the potentiometer (1) toward the

moved

minimum resistance position (0 ohms) until

Mark the 0 to 250 ohm potentiometer to

the machine starts to move. To reverse the

show the minimum and maximum resistance

direction of travel reverse the switch (2).

positions (0 ohms and 250 ohms respectively).

If the machine does not move and/or

The potentiometer should be at the maximum

increase in speed as the potentiometer (1)

resistance (250 ohms) when the test box is

is turned toward the minimum resistance

connected to the machine.

position (0 ohms) replace the EDC.

Operating Instructions

If the machine moves and increases speed,

Before making the following checks, ensure that

as the potentiometer (1) is turned toward

the machine is on flat ground with adequate

the minimum resistance position, the EDC

room for movement forward and reverse. With

is working correctly. Check for an electrical

the brake off, manually move the pump control

problem other than the EDC.

valve at the EDC (see the service manual).

Item

Description

Radio Shack Part No.

14-gauge wire, 4.8 m (15.75 ft)long (4)

16-gauge wire, length as required

Terminal strip

274-658

Battery clip (+red)

270-344

Battery clip (-black)

270-344

Clip, mini (2)

270-378

Box, 133.4 x 76.2 x 54.1 mm (5.25 x 3 x 2.13 in)

270-238

Item

Part Number

Description

8C-7647

Potentiometer, 0 - 250 ohms

8C-8023

MicroSwitch

081-7580

Resistor, 40 ohms (2)

JULY 2018 Diagnostic Tools

1-111

Diagnostic Tools

POWER TRAIN TOOLS

Transmission Analyzer III Group

Model Usage: Machines with electrical

European Union compliant, CE marked

• Determines if shift lever is functioning

transmission or pump controls

correctly on transmissions not controlled by

• Replaces discontinued 9U-7500 Transmission

autoshift electronic control feature

Warranty: Caterpillar ^®One Year

Analyzer II Group

• Capable of testing electronically actuated

• Used to electronically test components on

pumps installed on a hydraulic test bench by

transmission or pump

energizing the solenoids inside the pump

• Used with dealer supplied computer

Uses PC based software to control

•

• Used on Powershift planetary, Powershift

transmissions allowing easy updates to

countershaft, Individual ClutchModulation

support new transmissions, as they are

(ICM), Challenger, H-Series Motor Grader,

released

and Electronic Clutch Pressure Control (ECPC)

• Software updated annually to accommodate

transmissions

NewProductionIntroduction Software

• Used to test and adjust proportional valves

Subscription NETG5048

which control transmission (connects directly

• PC software with easy to use graphic

to solenoids with dealer supplied adapters)

interface provides step-by-step instruction for

• Operates and checks solenoid operation,

analyzer operation

electronic shift lever operation, and

• Allows use of mouse, rollerball, touchpad, and

transmission shifts

keyboard controls

• Performs automatic or manual testing for

• USB communications cable (included) allows

shorted or open solenoid coils (can also alert

for quick easy connection between analyzer

technician to intermittent problems with

and dealer supplied PC

solenoids)

• Designed and built for harsh shop

• Analyzer can activate solenoids in a timeline

environment

sequence

• Modulates current to 1 or all activated

References

solenoids at any point in time

• NEHS0996 Tool Operating Manual

• Analyzer outputs pulse width modulated

• NETG5048 Annual Software Subscription,

(PWM) current (required for Challenger and

Bench Testing Hydraulic Components

ECPC transmissions)

Part Number

Description

277-2362

Transmission Analyzer III Group

286-0755

USB Communications Cable

Hinged Hard Shell Carry Case

Optional Tools

1U-9479

Gear Shift Test Adapter Cable

1U-9480

Gear Shift Test Adapter Cable

1U-9482

Test Cable (ICM)

1U-9483

Test Cable (Challenger)

256-7623

Dozer Speed Sensor Cable

300-4993

Adapter Cable (17-pin to 14-pin) some R and T Series Track-Type Tractors

307-3542

Transmission Analyzer Adapter Cable

9U-7496

TestCable

9U-7497

TestCable

9U-7498

Extension Cable

Stub Harness

Model Usage: 120k, 140k, 160k

• Used to adapt TA3 Transmission Analyzer to

Reference

transmission for testing

Series-2 Motor Graders

• NEHS0996

Warranty: Caterpillar ^®One Year

Part No.

Description

Dimensions

Weight

514-9913

Stub Harness

75 x 300x 300(3x 12 x 12in)

2 kg (4.4 lb)

JULY 2018 Diagnostic Tools

1-113

Diagnostic Tools

POWERTRAINTOOLS

Specifications

• AC power: 110 - 240 VAC

• Minimum software required:

- Intel Pentium II 333 MHz processor or

• Minimumcurrentrequired: 10 amps

higher

• Power cord: 231 cm (91 in) long

- 128MB RAMor higher

• 286-0755 USB Cable: 203 cm (80 in) long

- 4.3 GB hard disk or higher

- CD drive or third generation DVD drive

• Operating temperature range: -18 to 60°C (0

- 15 in or larger Super VGA adapter and

to 140°F) ambient air

monitor

• Storage temperature range: -40 to 60°C (-40

• Suggested pointing device: Mouse, trackball,

to 140°F) ambient air

or touchpad

• Overcurrent protection: Current limiting

• Case: 52 x 45 x 22 cm (20.5 x 17.5 x 8.5 in)

electronic circuit

• Tester: 36 x 32 x 15 cm (14.25 x 12.5 x 6 in)

• Short protection: 30 amp quick-trip circuit

breaker

• Group weight: 6 kg (13.8 lb)

• PC software: Upgradable

• Tester weight: 4 kg (8.9 lb)

• Operating system: Windows 2000 or XP

• Required RAM: 1 MB

Applicable Models

• Articulated Trucks: D250E, D250E III, D300E,

• Scrapers: 621E, 621F, 623E, 623F, 627B, 627E,

D300E III,D350E, D350E III D400E, D400E III,

627F, 631E, 631F, 633E, 633F, 637D, 637E,

725, 730, 735, 740

637F, 639D, 639F, 651E, 657B, 657E

• Backhoe Loaders: 416, 426, 428, 436, 438,

• Off-Highway Trucks: 725, 730, 768C, 769C,

446, 446B-001, 446B-2500

772B, 773B, 773D, 776, 776B, 777, 777B,

777D, 785, 789, 793,

• Challenger Tractors: 35, 45, 55MT 700 Series,

MT 800 Series

• Wheel Loaders: 910, 910E, 910F, 918F, 924F,

924G, 924GII, 928F, 928G, 928GII, 936, 936F,

• Compactors: 815F, 816F, 825G, 826G, 836G

938F, 938G, 938GII, 950F, 950G, 960F, 962G,

• Dozers: D5M, D6M, D6R, D7R, D8R, D10R,

966F, 966G, 970F, 972G, 980F, 980G, 988F,

D11N, D11R

988G, 988GII, 990, 992D, 992G, 994D, 994G

• H-Series Motor Graders: 12H, 14H, 24H,

• Wheel Skidders: 515, 520D, 522D, 525, 525B,

120H, 135H, 140H, 143H, 160H, 163H

545

• Integrated Tool Carriers: IT12, IT12B, IT12F,

• Wheel Tractors: 814F, 824G, 834G,836G, 844,

IT14, IT14B, IT14F, IT18F, IT24F, IT24G, IT28F,

854

IT28G, IT38F, IT38G, IT62G

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Diagnostic Tools

POWERTRAINTOOLS

Optional Tools

9U-7497

Test Cable: 12 2-pin Sure-seal (Used with 9U-7498 Extension Cable)

9U-7498

Extension Cable

453-6035

Stub harness for 730C transmissions (Requires 306-0397 Extension Harness)

Stub harness for 772G transmissions

459-4086

(Requires 306-0397 Extension Harness)

Stub harness for 525, 535, 545, and 555 D series transmissions

460-4069

(Requires 306-0397 Extension Harness)

Stub Harness Used with Transmission Analyzer 3

(Requires 306-0397 extension harness)

525-6655

400 x 400 x 200 mm (16 x 16 x 8 in), 3 kg (6.6 lb)

Model Usage: 966M XE, Warranty: One Year

TA3 Stub Harness for K-Series Scrapers,

518-7986

100 x 200 x 50 mm (4 x 8 x 2 in), 1 kg (2.2 lb)

Used with transmission analyzer 3 and 966M XE

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1-115

Diagnostic Tools

POWER TRAIN TOOLS

Test Harnesses

Model Usage: E(L)200B, E(L)240B, and E(L)300B

Allows access to electrical control signals to be

• SENR4843, Electronic Power Unit Module for

Excavators

checked for correct operation and measurement

E(L)240B

of voltages, current, resistance and continuity

Warranty: Caterpillar ^®One Year

• SENR4871, Electronic Power Unit Module for

E(L)300B

References

• SENR4527, Testing and Adjusting Module for

• NEHS0546, Tool Operating Manual,

E(L)200B

Adjustment to Electronic Power Unit Control

System

Item

Part Number

Description

Use

To check the Proportional Reducing Valve (PRV)

099-0050

Test Harness

on E(L)200B Excavator

Adapter Harness

Model Usage: D6T, D8T, D10T2

• Used to shift transmission and measure speed

Specifications

sensor signals during a bench test

Warranty: Caterpillar ^®One Year

• 75 x 30 x 300 mm (2.95 x 1.18 x 11.81 in)

• Used with the 277-2362 Transmission

• Weight: 1 kg (2.2 lb)

Analyzer III Group

• 40 Pin connector plugs into 306-0397

extension cable

Part Number

Description

453-4703

Adapter Harness

Adapter Cable

Model Usage: All OEM transmissions using

• Used to shift transmission and measure speed

• Speed sensor plugs can also be connected

A4:M1 ECM

sensor output signals during bench test

into the Transmission Analyzer III using the

2-pin Deutsch receptacles

Warranty: Caterpillar ^®One Year

• Used with 277-2362 Transm Analyzer III Group

• Ground clamp connects to ground point on

• 40-pin connector plugs into 306-0397

transmission

Extension Cable

• Main harness approximately 300 mm

• 70-pin connector plugs into machine harness

(11.81 in) long

J1 connector

• Speed sensor breakouts approximately

• 8-speed sensor breakout plugs

600 mm (23.6 in) long

• Can be back-probed with multimeter to check

speed sensor voltage and frequency signals

Part Number

Description

311-4929

Adapter Cable

Dozer Speed Sensor Cable

Model Usage: D6M, D6R, and D6T Track-Type

• Used to shift transmission and measure speed

• One end plugs directly into transmission

Tractors

sensor signals during a bench test

control connector

Warranty: Caterpillar ^®One Year

• Used with discontinued 9U-7500 Transmission

• Speed sensor connectors plug directly into

Analyzer II Group

multimeter

Part Number

Description

256-7623

Dozer Speed Sensor Cable

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1-117

Diagnostic Tools

POWERTRAINTOOLS

Extension Adapter Cable

Model Usage: All models with electronic

• Used with 277-2362 Transmission Analyzer

• Speed sensor breakout cable allows sensor

controls

III Group and individual machine test adapter

readouts with Transmission Analyzer III

cables that have speed sensor capability

software

Warranty: Caterpillar ^®One Year

• Provides longer connection between machine

test adapter cable/Transmission Analyzer III

Part Number

Description

306-0397

Extension Adapter Cable

Adapter Cable

Model Usage: 777F Off-Highway Truck

• Used to shift transmission and measure speed

• Enables technician to monitor output speed

sensor outputs during bench test

sensors via Transmission Analyzer III

Warranty: Caterpillar ^®One Year

• Used with 277-2362 Transmission Analyzer III

• Ground clamp connects to ground point on

Group and 306-0397 Extension Cable

transmission

• Adapter connects 306-0397 Extension Cable

• Main harness length: 30 cm (11.8 in)

to the transmission bulkhead connector

• Speed sensor breakout harness length: 60 cm

• Speed sensor breakouts allow multimeter

(23.6 in)

readouts

Part Number

Description

305-7401

Adapter Cable

Model Usage: 773-775F Off-Highway Truck

• Used to shift transmission and measure speed

• Enables technician to monitor output speed

sensor outputs during bench test

sensors with Transmission Analyzer III

Warranty: Caterpillar ^®One Year

• Used with 277-2362 Transmission Analyzer III

• Ground clamp connects to ground point on

Group and 306-0397 Extension Cable

transmission

• Adapter connects 306-0397 Extension Cable

• Main harness length: 30 cm (11.8 in)

to the transmission bulkhead connector

• Speed sensor breakout harness length: 60 cm

• Speed sensor breakouts allow multimeter

(23.6 in)

readouts

Part Number

Description

304-9164

Adapter Cable

Adapter Cable Assembly

Model Usage: TH48FT-E70 Oil-Field Transmission

• Used to shift transmission during bench test

• Ground clamp connects to ground point on

transmission

Warranty: Caterpillar ^®One Year

• Used with 277-2362 Transmission Analyzer III

Group and 9U-7498 Extension Cable

• Overall length: 30 cm (11.8 in)

• Connects to 31-pin 9U-7498 Extension Cable,

• Material: 18 gauge wire

17-pin transmission bulkhead connector, and

2-pin lock-up clutch solenoid receptacle

Part Number

Description

304-9169

Adapter Cable Assembly

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Diagnostic Tools

POWER TRAIN TOOLS

Adapter Cable Assembly

Model Usage: M-Series Motor Graders

• Used to shift transmission and measure speed

• Speed sensor breakouts allow for multimeter

sensor outputs during bench test

readouts

Warranty: Caterpillar ^®One Year

• Used with 277-2362 Transmission Analyzer III

• Enables technician to monitor output speed

Group and 306-0397 Extension Cable

sensors using Transmission Analyzer III

• Adapter connects 306-0397 Extension Cable

• Main harness length: 30 cm (11.8 in)

to the parking brake solenoid, shift solenoid,

• Speed sensor breakout harness length: 60 cm

and speed sensor connectors on transmission

(23.6 in)

• Ground clamp connects to ground point on

transmission

Part Number

Description

306-6388

Adapter Cable Assembly

Adapter Harness

Model Usage: 140M2

• Used to shift transmission and measure speed

• Speed sensor breakouts allow for multimeter

sensor outputs during bench test

readouts

Warranty: Caterpillar ^®One Year

• Used with 277-2362 Transmission Analyzer III

• Enables technician to monitor output speed

Group and 306-0397 Extension Cable

sensors using Transmission Analyzer III

• Adapter connects306-0397 Extension Cable to

Specifications

the shift solenoids, and speed sensors on the

• Dimensions: 107.6 x 60.24 x 300 mm (4.24 x

intermediate transmission harness

2.37 x 11.81 in)

• Ground clamp connects to ground point on

• Weight: 1.5 kg (3.3 lb)

transmission

Part Number

Description

460-2395

Adapter Harness

Transmission Test Harness

ModelUsage: 950 through 982 L and Mseries

• Used to shift transmission and measure speed

• Enables technician to monitor output speed

Wheel Loaders

sensor outputs during bench test

sensors with Transmission Analyzer III

Warranty: Caterpillar ^®Six Months

• Used with 277-2362 Transmission Analyzer III

• Ground clamp connects to ground point on

Group and 306-0397 Extension Cable

transmission

• Adapter connects 306-0397 Extension Cable

• Main harness length: 30 cm (11.8 in)

to the intermediate transmission harness

• Speed sensor breakouts for multimeter usage

Part No.

Models

442-2465

950L, 950M, 962L, 962M

442-2466

966L, 966M, 972L, 972M, 980L, 980M, 982L, 982M

Adapter Cable

Model Usage: 793F

• Used to shift transmission and measure speed

• Speed sensor breakouts allow multimeter

sensor outputs during bench test

readouts

Warranty: One Year

• Used with 277-2362 Transmission Analyzer III

• Capability to monitor output speed sensors

Group and 306-0397 Extension Cable Adapter

with Transmission Analyzer III

• Connects 333-6413 extension cable to the

• Ground clamp connects to ground point on

transmission bulkhead

transmission

Part Number

Description

333-6413

Adapter Cable

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Caterpillar. Dealer service tools catalog (2018) - page 3